Cylinder Heads Installation
InstallationBoth sides
1. Position the cylinder head gasket on the block.
RH side
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 8 new 12 mm bolts and tighten in the sequence shown in 2 stages.
^ Stage 1: Tighten to 12 Nm (9 ft. lbs.).
^ Stage 2: Tighten to 25 Nm (18 ft. lbs.).
3. Install 2 new 8 mm bolts.
^ Tighten to 32 Nm (24 ft. lbs.).
4. Tighten the 8 12 mm bolts in the sequence shown in 2 stages.
^ Stage 1: Tighten the bolts 90 degrees.
^ Stage 2: Tighten the bolts an additional 90 degrees.
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.
^ Tighten to 12 Nm (9 ft. lbs.).
LH side
7. CAUTION: To avoid damage to the timing chain cassette, an assistant will be required to help position the cylinder head in the vehicle.
NOTE: New cylinder head bolts must be installed. They are a torque to yield design and cannot be reused.
Install the cylinder head. Install 8 new 12 mm bolts and tighten in the sequence shown in 2 stages.
^ Stage 1: Tighten to 12 Nm (9 ft. lbs.).
^ Stage 2: Tighten to 25 Nm (18 ft. lbs.).
8. Install 2 new 8 mm bolts.
^ Tighten to 32 Nm (24 ft. lbs.).
9. Tighten the 8 12 mm bolts in the sequence shown in 2 stages.
^ Stage 1: Tighten the bolts 90 degrees.
^ Stage 2: Tighten the bolts an additional 90 degrees.
10. 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.
11. Install the LH side cassette bolt.
^ Tighten to 19 Nm (14 ft. lbs.).
Both sides
12. Install both of the exhaust manifolds gaskets, the exhaust manifolds and the nuts.
^ Tighten to 22 Nm (16 ft. lbs.).
13. NOTE: Apply dielectric compound to the inside of the spark plug wire boots.
Connect all of the spark plug wires to the spark plugs.
14. NOTE: LH side shown, RH side similar.
Install the 4 catalytic converter to exhaust manifold nuts.
^ Tighten to 40 Nm (30 ft. lbs.).
15. Install the engine noise shield.
RH side
16. Install the engine ground strap and the bolt.
^ Tighten to 10 Nm (89 inch lbs.).
17. Position the engine wiring harness and install the bolts.
^ Tighten to 47 Nm (35 ft. lbs.).
18. NOTE: Inspect the O-ring seal. Install a new O-ring seal if necessary.
Install the thermostat housing and the bolts.
^ Tighten to 11 Nm (8 ft. lbs.).
19. Position the coolant bypass hose clamp.
20. Install the upper radiator hose.
21. Connect the Engine Coolant Temperature (ECT) sensor electrical connector.
22. Install the heater hose to the thermostat housing.
23. Install the generator mounting bracket assembly and the bolts.
^ Tighten to 42 Nm (31 ft. lbs.).
24. Connect the generator electrical connections and install the push pin.
^ Tighten to 8 Nm (71 ft. lbs.).
LH side
25. Install the oil level indicator tube and bolt.
^ Tighten to 10 Nm (89 inch lbs.).
26. Install the coil bracket and the bolts.
^ Tighten to 89 Nm (10 inch lbs.).
27. Install the accessory bracket and the bolts.
^ Tighten to 42 Nm (31 ft. lbs.).
28. Install the bolts.
^ Tighten to 10 Nm (89 inch lbs.).
29. Connect the radio ignition interference capacitor electrical connector.
Both sides
30. Install the accessory drive belt tensioner.
31. 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).
32. Remove the retainer and position the A/C manifold tube bracket aside.
33. CAUTION: Do not rotate the engine counterclockwise. Rotating the engine counterclockwise will result in incorrect timing of the engine.
NOTE: The special tool must be installed on the damper and should contact the engine block, this positions the engine at TDC.
Install the special tool.
34. NOTE: Leave the top 2 special tool clamp bolts loose.
Install the special tools on the rear of the RH cylinder head.
35. 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.
36. Install the special tool.
37. 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 303 565, tighten the camshaft bolt.
^ Tighten to 61 Nm (45 ft. lbs.).
38. Install the RH camshaft tensioner.
^ Tighten to 44 Nm (32 ft. lbs.).
39. NOTE: Leave the top 2 special tool clamp bolts loose.
Install the special tools on the front of the LH cylinder head.
40. 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.
41. Install the special tool.
42. Tighten the bolts.
1 Tighten the special tool top 2 clamp bolts to 10 Nm (89 inch lbs.).
2 Tighten the camshaft bolt.
^ Tighten to 85 Nm (63 ft. lbs.).
43. Install the LH camshaft tensioner.
^ Tighten to 44 Nm (32 ft. lbs.).
44. Install the A/C manifold tube assembly bracket and the nut.
^ Tighten to 20 Nm (15 ft. lbs.).
45. Install the roller followers.
46. Fill and bleed the engine cooling system.