Part 2 of 2

Cylinder Head Continued

Installation

Both sides





1. Position the cylinder head gasket on the block.





2. CAUTION: To avoid damage to the timing chain cassette an assistant will be required to help position the cylinder head in the vehicle.

CAUTION: On the RH side, when lifting the cylinder head be careful to avoid contacting the A/C tube.

NOTE: New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused.

Install the cylinder head. Install new 12 mm (0.48 inch) bolts and tighten in the sequence shown.





3. Install two new 8 mm (0.32 inch) head bolts.





4. Tighten the eight 12 mm (0.48 inch) bolts in the sequence shown in two stages.
^ Tighten the bolts 90 degrees.
^ Tighten the bolts an additional 90 degrees.

RH side





5. CAUTION: The camshaft gear must turn freely on the camshaft. DO NOT tighten the bolt at this time

Remove the rubber band. Install the camshaft sprocket and bolt.





6. Install the RH side cassette bolt.

LH side





7. CAUTION: The camshaft gear must turn freely on the camshaft. DO NOT tighten the bolt at this time.

Remove the rubber band. Install the camshaft sprocket and bolt.





8. Install the LH side cassette bolt.

Both sides





9. Install both of the exhaust manifolds and caskets.





10. NOTE: Apply dielectric compound to the inside of the spark plug wire boots.

Connect all of the spark plug wires to the spark plugs.





11. NOTE: LH side shown, RH side similar.

Install the four catalytic converter-to-exhaust manifold nuts.





12. Install the engine noise shield.

RH side





13. Install the engine Ground strap.





14. Position the engine wiring harness and install the bolts.





15. NOTE: Inspect the O-ring. Install a new O-ring if necessary.

Install the thermostat housing.





16. Position the coolant bypass hose clamp.





17. Install the upper radiator hose.





18. Connect the engine coolant temperature (ECT) sensor electrical connector.





19. Install the heater hose to the thermostat housing.





20. Install the generator mounting bracket assembly.





21. Install the accessory drive belt tensioner.





22. Connect the generator electrical connections and install the pushpin.

LH side





23. Install the oil level indicator tube and bolt.





24. Install the coil bracket and the bolts.





25. Install the accessory bracket.





26. Install the bolts.





27. Connect the radio ignition interference capacitor electrical connector.

Both sides
28. Install the accessory drive belt.

29. NOTE: You must retime the LH and RH camshafts when either camshaft is disturbed.

Turn the crankshaft clockwise to position the number one cylinder at top dead center (TDC).





30. Remove the retainer and position the A/C manifold tube bracket aside.





31. NOTE: The special tool must be installed on the damper and should contact the engine block, this positions the engine at TDC.

NOTE: Late build pulley shown, early build pulley similar.

Install the special tool.





32. NOTE: Leave the top two special tool clamp bolts loose.

Install the special tools on the rear of the RH cylinder head.





33. NOTE: The camshaft timing slots are off-center.

Position the camshaft timing slots below the centerline of the camshaft to correctly fit the special tools, and install the special tools on the front of the RH cylinder head.





34. Install the special tool.





35. CAUTION: The RH camshaft sprocket bolt is a LH threaded bolt.

Tighten the bolts.
1. Tighten the special tool top clamp bolts to 10 Nm (89 inch lbs.).
2. Using the special tool with the Camshaft Sprocket Nut Socket, tighten the camshaft bolt.





36. Install the RH camshaft tensioner.





37. NOTE: Leave the top two special tool clamp bolts loose.

Install the special tools on the front of the LH cylinder head.





38. NOTE: The camshaft timing slots are off-center.

Position the camshaft timing slots below the centerline of the camshaft to correctly fit the special tools, and install the special tools on the rear of the LH cylinder head.





39. Install the special tool.





40. Tighten the bolts.
1. Tighten the special tool top two clamp bolts to 10 Nm (89 inch lbs.).
2. Tighten the camshaft bolt.





41. Install the LH camshaft tensioner.





42. Install the A/C manifold tube assembly bracket.
43. Install the roller followers.
44. Fill and bleed the engine cooling system.