Cylinder Head - Installation
Cylinder Head
Installation
All cylinder heads
1. NOTICE: Make sure all coolant residue and foreign material are cleaned from the block surface and cylinder bore. Failure to follow these instructions may result in engine damage.
NOTICE: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry. Failure to follow these instructions may result in engine damage.
NOTICE: The cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield designed and cannot be reused. Failure to follow these instructions may result in engine damage.
NOTE: Do not turn the crankshaft until instructed to do so.
NOTE: LH shown, RH similar.
Using the Cylinder Head Alignment Pins, position the cylinder head gaskets and cylinder heads over the dowels and install the cylinder head bolts loosely.
2. Tighten the 10 LH cylinder head bolts in 6 stages, in the sequence shown.
- Stage 1: Tighten to 40 Nm (30 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
- Stage 3: Loosen all bolts a minimum of one full turn.
- Stage 4: Tighten to 40 Nm (30 lb-ft).
- Stage 5: Tighten an additional 90 degrees.
- Stage 6: Tighten an additional 90 degrees.
3. Tighten the 10 RH cylinder head bolts in 6 stages, in the sequence shown.
- Stage 1: Tighten to 40 Nm (30 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
- Stage 3: Loosen all bolts a minimum of one full turn.
- Stage 4: Tighten to 40 Nm (30 lb-ft).
- Stage 5: Tighten an additional 90 degrees.
- Stage 6: Tighten an additional 90 degrees.
4. Remove the Cylinder Head Remover/Installer from both ends of the cylinder head being serviced.
5. NOTE: Lubricate the hydraulic lash adjusters with clean engine oil prior to installation.
Install the 16 hydraulic lash adjusters in their original locations.
RH cylinder head
6. Install 8 new exhaust manifold-to-cylinder head studs.
- Tighten to 12 Nm (106 lb-in).
7. Install new exhaust manifold gaskets, the exhaust manifold and install the 8 new nuts in the sequence shown.
- Tighten to 20 Nm (177 lb-in).
LH cylinder head
8. Install 8 new exhaust manifold-to-cylinder head studs.
- Tighten to 12 Nm (106 lb-in).
9. Install new exhaust manifold gaskets, the exhaust manifold and install 8 new nuts in the sequence shown.
- Tighten to 20 Nm (177 lb-in).
All cylinder heads
10. NOTICE: Timing chain procedures must be followed exactly or damage to valves and pistons will result.
NOTICE: Prior to installation, inspect the tensioner-sealing bead for seal integrity. If cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner or engine damage may occur.
Compress the tensioner plunger, using a vise.
11. Install a retaining clip on the tensioner to hold the plunger in during installation.
12. Remove the tensioner from the vise.
13. If the copper links are not visible, mark 1 link on one end and 1 link on the other end and use as timing marks.
14. Install the crankshaft sprocket, making sure the flange faces forward.
15. Install the timing chain guides.
1. Position the LH timing chain guide.
2. Install and tighten the 2 LH bolts.
3. Position the RH timing chain guide.
4. Install and tighten the 2 RH bolts.
- Tighten to 10 Nm (89 lb-in).
16. Rotate the RH camshaft sprocket until the timing mark is approximately at the 11 o'clock position. Rotate the LH camshaft sprocket until the timing mark is approximately at the 1 o'clock position.
17. NOTE: The No. 1 cylinder is at Top Dead Center (TDC) when the stud on the engine block fits into the slot in the handle of the Crankshaft Holding Tool.
Position the crankshaft so the No. 1 cylinder is at TDC with the Crankshaft Holding Tool.
18. Remove the Crankshaft Holding Tool.
19. Position the LH (inner) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
20. Install the LH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
21. NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.
Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner and the 2 bolts.
- Tighten to 25 Nm (18 lb-ft).
22. Remove the retaining clip from the LH timing chain tensioner.
23. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
24. Install the RH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
25. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and the 2 bolts.
- Tighten to 25 Nm (18 lb-ft).
26. Remove the retaining clip from the RH timing chain tensioner.
27. Make sure that the copper (marked) chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprocket.
28. Install the crankshaft sensor ring on the crankshaft.
29. NOTE: Camshaft roller follower is removed for clarity.
Install the Valve Spring Compressor Spacer between the valve spring coils to prevent valve stem seal damage.
30. NOTICE: The camshaft roller followers must be installed in their original locations. Failure to follow these instructions may result in engine damage.
NOTE: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. For additional information, refer to Engine Engine - Removal.
NOTE: It may be necessary to push the valve down while compressing the spring.
NOTE: Position the cam lobe away from the valve stem prior to installing each camshaft roller follower.
Use the Valve Spring Compressor to compress the valve springs, and install the camshaft roller follower.
31. NOTE: The camshaft roller followers must be installed in their original locations.
Repeat the previous 3 steps for each camshaft roller follower.
32. Install the 8 spark plugs. For additional information, refer to Engine Ignition - 4.6L (2V) Spark Plugs.
33. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
NOTE: If the engine front cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
NOTE: Make sure that the engine front cover gasket is in place on the engine front cover before installation.
Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface and the oil pan-to-cylinder block surface, at the locations shown.
34. Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners finger-tight.
35. Tighten the 15 front cover fasteners in the sequence shown to 25 Nm (18 lb-ft).
36. Loosely install the 4 front oil pan bolts, and tighten the bolts in 2 stages, in the sequence shown.
- Stage 1: Tighten to 20 Nm (177 lb-in).
- Stage 2: Tighten an additional 60 degrees.
37. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.
Inspect and clean the valve cover sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
38. Apply instant adhesive completely around the gasket groove in the LH valve cover. Install the new valve cover gasket.
39. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
40. Position the LH valve cover and gasket on the cylinder head and install the fasteners loosely.
41. Position the LH valve cover and tighten the 11 fasteners in the sequence shown to 10 Nm (89 lb-in).
42. Apply instant adhesive completely around the gasket groove in the RH valve cover. Install the new valve cover gasket.
43. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
44. Position the RH valve cover and gasket on the cylinder head and install the 11 fasteners loosely.
45. Position the RH valve cover and tighten the 11 fasteners in the sequence shown to 10 Nm (89 lb-in).
46. Position the accessory drive belt idler pulley and install the bolt.
- Tighten to 25 Nm (18 lb-ft).
47. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
48. Using the Front Cover Oil Seal Installer, Crankshaft Front Oil Seal Installer and Crankshaft Vibration Damper Installer, install a new crankshaft front seal.
49. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
50. Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.
51. NOTE: Use a suitable Strap Wrench (such as 303-D055) to hold the pulley while tightening the bolt.
Tighten the new crankshaft pulley bolt in 4 stages.
- Stage 1: Tighten to 120 Nm (89 lb-ft).
- Stage 2: Loosen one full turn.
- Stage 3: Tighten to 50 Nm (37 lb-ft).
- Stage 4: Tighten an additional 90 degrees.
52. Position the coolant pump pulley on the coolant pump and install the 4 bolts.
- Tighten to 25 Nm (18 lb-ft).
53. NOTE: RH shown, LH similar.
Install the radio frequency interference capacitors and the nuts.
- Tighten to 25 Nm (18 lb-ft).
54. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation.
Using a new O-ring seal, install the oil level indicator tube and the bolt.
- Tighten to 10 Nm (89 lb-in).
55. Install the oil level indicator and tube support bracket nut.
- Tighten to 10 Nm (89 lb-in).
56. Roughly position the engine control sensor wiring harness and mount it on the valve cover studs.
57. Connect the CKP sensor electrical connector.
58. Connect the Engine Oil Pressure (EOP) switch electrical connector and wiring harness retainer.
59. Connect the KS electrical connector.
60. Connect the RH radio frequency interference capacitor electrical connector.
61. Connect the CMP sensor electrical connector.
62. Connect the LH radio frequency interference capacitor and Cylinder Head Temperature (CHT) sensor electrical connectors.
63. NOTE: LH shown, RH similar.
If equipped, install the cylinder block drain plugs.
- Tighten to 20 Nm (177 lb-in).
64. If equipped with cylinder block drain plugs, install the RH engine support insulator.
- Tighten to 80 Nm (59 lb-ft).
65. Install the Engine Lifting Bracket Set.
66. Install the Engine Lifting Bracket Set.
67. Install the Engine Lifting Bracket Set and remove the engine from the work stand.
68. Lower the engine onto wooden blocks.
69. Install the Engine Lifting Bracket and raise the engine.
70. Install the flexplate and the 6 bolts. Tighten the bolts in 2 stages in the sequence shown.
- Stage 1: Tighten to 20 Nm (177 lb-in).
- Stage 2: Tighten to 80 Nm (59 lb-ft).
71. Install the engine. For additional information, refer to Engine Engine - Removal.