Part 1 of 2
Cylinder Heads
Special Tool(s)
Material
NOTE: Before cylinder head installation, use metal surface cleaner and a suitable plastic or wooden scraper to clean the sealing surfaces. All sealing surfaces must be clean. Make sure coolant and oil passages are clear.
All vehicles
1. Install new cylinder head gaskets.
2. NOTE: LH shown; RH similar.
NOTE: Lubricate the new bolt heads and threads. Use clean engine oil.
Install the LH and RH cylinder heads and tighten the bolts in six stages in the sequence shown.
^ Stage 1: Tighten to 40 Nm (30 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees.
^ Stage 3: Loosen the bolts a minimum of one full turn.
^ Stage 4: Tighten to 40 Nm (30 ft. lbs.).
^ Stage 5: Tighten an additional 90 degrees.
^ Stage 6: Tighten an additional 90 degrees.
Engines with ratcheting timing chain tensioners
3. CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.
CAUTION: Do not compress the ratchet assembly. This will damage the ratchet assembly.
NOTE: LH shown, RH similar.
Compress each tensioner plunger, using an edge of a vise.
4. Using a small screwdriver or pick, push back and hold the ratchet mechanism.
5. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
6. Install a paper clip into the hole of each tensioner housing to hold the ratchet assembly and plunger in during installation.
^ Remove the tensioner from the vise.
Engines with non-ratcheting timing chain tensioners
7. Compress the tensioner plunger, using a vise.
8. Install a retaining clip on the tensioner to hold the plunger in during installation.
9. Remove the tensioner from the vise.
All engines
10. If the copper links are not visible, mark one link on one end and one link on the other end, and use as timing marks.
11. Install the timing chain guides.
12. Rotate the LH camshaft timing sprocket until the timing mark is approximately at the 12 o'clock position. Rotate the RH camshaft timing sprocket until the timing mark is at approximately the 11 o'clock position.
13. CAUTION: Unless otherwise instructed, at no time when the timing chains are removed and the cylinder heads are installed is the crankshaft or camshaft to be rotated. Severe piston and valve damage will occur.
Using the special tool, position the crankshaft.
14. Install the crankshaft sprocket with the flange facing forward.
15. Install the LH and RH timing chains onto the crankshaft sprocket, aligning the one copper link on the timing chain with the slot on the crankshaft sprocket.
16. NOTE: If necessary, adjust the camshaft sprocket slightly to obtain timing mark alignment.
Position the LH and RH timing chains on the camshaft sprockets. Make sure the copper-colored links align with the camshaft sprocket timing marks.
17. Position the LH and RH timing chain tensioner arms on the dowel pins. Position the timing chain tensioner assemblies, and install the bolts.
Engines with ratcheting timing chain tensioners
18. Remove the retaining clip from the timing chain tensioners.
Engines with non-ratcheting timing chain tensioners
19. Remove the retaining clips from the timing chain tensioners.
All engines
20. As a post-check, verify correct alignment of all timing marks.
21. Position the crankshaft sensor ring on the crankshaft.
22. NOTE: If the engine front cover is not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can result in future oil leakage.
Apply silicone gasket and sealant in the locations shown.
23. Install the engine front cover and tighten the bolts in the sequence shown.
24. Install the four oil pan bolts and tighten in the sequence shown.
^ Stage 1: Tighten to 2 Nm (18 inch lbs.).
^ Stage 2: Tighten to 20 Nm (15 ft. lbs.).
^ Stage 3: Tighten an additional 60 degrees.
25. CAUTION: If reusing the roller followers, install them in their original locations.
Position the piston of the cylinder in which the roller followers are being installed at the bottom of the stroke and the camshaft lobe at the base circle.
26. Using the special tool, compress the intake valve spring and install the roller follower.
27. Using the special tool, compress the exhaust valve spring and install the roller follower.
28. Repeat the above steps to install all of the roller followers.
29. NOTE: If the valve cover is not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can result in future oil leakage.
Apply silicone gasket and sealant in the locations shown.
30. NOTE: RH shown; LH similar.
Install the valve covers and tighten the bolts in the sequence shown.
31. Install the belt idler pulley.
32. Lubricate the front oil seal and the engine front cover with clean engine oil.
33. Using the special tools, install the front oil seal.
34. Apply silicone gasket and sealant to the Woodruff key on the crankshaft pulley.
35. Using the special tool, install the crankshaft pulley.
36. Install the crankshaft pulley and tighten the bolt in four stages.
^ Stage 1: Tighten to 90 Nm (66 ft. lbs.).
^ Stage 2: Loosen the bolt one full turn.
^ Stage 3: Tighten to 50 Nm (37 ft. lbs.).
^ Stage 4: Tighten an additional 90 degrees.