Cylinder Head Installation

CYLINDER HEAD REPLACEMENT (IN-VEHICLE)

INSTALLATION

NOTICE: Set crankshaft to 60 degrees before top-dead center or after TDC to prevent valve to piston contact.





1. Set crankshaft to 60 degrees before or after Top Dead Center (TDC)





2. Install head gasket placing OBEN facing top.

IMPORTANT: Always use new cylinder head bolts.

3. Install cylinder head, aligning it on the dowels.
4. Lightly apply clean engine oil to threads and to the bottom side of the flange of head bolts and allow oil to drain before installing.

Cylinder Head Tightening Sequence:

5. Install and tighten cylinder head bolts in sequence.
Torque:
Cylinder Head Bolts: 30 Nm (22 ft. lbs.) + 155 degrees





6. Coat front cylinder head bolts with Loctite 242.
7. Install front cylinder head bolts.
Torque:
Cylinder Head Front Chain case Bolts: 20 Nm (15 ft. lbs.)





8. Position exhaust camshaft with the offset slot at the 2 O'clock position.





9. Position intake camshaft with the offset slot at the 11 O'clock position.





10. Pull up timing chain and install around intake camshaft sprocket with the copper link lined up with the INT diamond timing mark.
11. Install sprocket onto camshaft and align with offset slot.

NOTICE: The camshaft sprocket bolt is not reusable, it is a Torque-To-Yield (TTY) bolt and must be discarded to prevent premature failure.

12. Install new camshaft sprocket bolt, do not tighten.





13. Route chain around crankshaft sprocket and align silver link to the timing mark.

NOTICE: There is a 2nd design adjustable guide with a contact pad for the 2nd design notched tensioner. A 2nd design guide should be used only with a 2nd design tensioner.





14. Install adjustable timing chain guide through opening on top of cylinder head and install chain guide bolt.
Torque:
Timing Chain Guide (Adjustable) Bolt: 10 Nm (89 inch lbs.)





15. Route timing chain around exhaust camshaft sprocket with the silver link lined up with offset slot
16. Install sprocket onto camshaft and align with offset slot.





NOTICE: The camshaft sprocket bolt is not reusable, it is a Torque-to-Yield (TTY) bolt and must be discarded to prevent premature failure.

17. Install new camshaft sprocket bolt, do not tighten.

NOTICE: Use a 24 mm wrench to support the camshaft while applying torque to camshaft sprocket bolt. Do not torque camshaft bolts against timing chain, as it may damage the timing chain.

IMPORTANT: Ensure that all the timing marks and colored links are aligned properly before proceeding to the next step.

18. Tighten intake and exhaust camshaft sprocket bolts
Torque:
Camshaft Sprocket Bolts: 85 Nm (63 ft. lbs.) + 30 degrees





19. Install fixed guide and install bolt.
Torque:
Timing Chain Guide (Fixed) Bolts: 10 Nm (89 inch lbs.)





20. Apply Loctite PST565 to plug threads.
21. Install fixed timing chain guide bolt access hole plug.
Torque:
Timing Chain Guide Bolt Access Hole Plug: 40 Nm (30 ft. lbs.)





NOTICE: There is a 2nd design tensioner with a notch at the plunger end of the tensioner. this tensioner should be used only with the 2nd design adjustable guide.

22. Reset timing chain tensioner by depressing plunger.
23. Install sealing ring onto tensioner and install.
Torque:
Timing Chain Tensioner Bolts: 75 Nm (55 ft. lbs.)
24. Gently tap top of chain, between the camshaft sprockets with hand. This will engage tensioner onto adjustable chain guide.





25. Install upper timing chain guide and bolts.
Torque:
Timing Chain Guide (Upper) Bolts: 10 Nm (89 inch lbs.)





IMPORTANT: Ensure that all the timing marks and colored links are aligned properly before proceeding to the next step.

26. Install front cover gasket and front cover.
27. Install front cover bolts.
Front Cover-to-Block Bolts: 25 Nm (18 ft. lbs.)





28. Install water pump bolt.
Water Pump Bolts: 25 Nm (18 ft. lbs.)





29. Install drive belt tensioner and belt.
Drive Belt Tensioner Bolt: 50 Nm (33 ft. lbs.)





30. Install engine mount bracket onto engine and install bolts.
Torque:
Engine Mount Bracket-to-Engine Bolts: 90 Nm (66 ft. lbs.)





31. Install engine mount assembly-to-side rail and install fasteners.
Torque:
Engine Mount-to-Body Bolts: 55 Nm (41 ft. lbs.)





32. Lower engine and align engine mount bolts.
33. Install engine mount bolts-to-bracket bolts.
Torque:
Engine Mount-to-Engine Mount Bracket Bolts: 55 Nm (41 ft. lbs.)
34. Remove floor jack.





35. Raise vehicle.

NOTICE: Misalignment of the keyway may cause damage to oil pump.

36. Install crankshaft damper.
36.1. Lubricate front oil seal and seal surface of crankshaft balancer with engine oil supplement.
36.2. Install damper onto crankshaft indexing keyway. Use care to properly align keyway and flats on the damper with oil pump drive.





NOTICE: It may be necessary to lower the engine slightly with a crow bar so that bolt-head clears frame rail.

36.3. Install new crankshaft damper pulley bolt.
Torque:
Crankshaft Damper Pulley Bolt: 100 Nm (74 ft. lbs.) + 75 degrees





37. Install drive belt.





38. Install A/C line clamps.
39. Install right wheel splash shield.





40. Install tire/wheel.
40.1. Hand tighten all five wheel bolts.
40.2. Use a torque wrench to initial tighten wheel bolts using a crisscross pattern.
Torque:
Wheel Bolts (Initial Torque): 63 Nm (46 ft. lbs.)
40.3. Use a torque wrench to final tighten wheel bolts using a crisscross pattern.
Torque:
Wheel Bolts (Final Torque): 125 Nm (92 ft. lbs.)
41. Install wheel cover.





42. Lower vehicle.
43. Install camshaft cover. Ensure that camshaft cover seals are properly seated in cover.
44. Install cover bolts and ground strap nut.
Torque:
Camshaft Cover Bolts: 10 Nm (89 inch lbs.)





45. Install power steering pump.
Torque:
Power Steering Pump Bolts: 25 Nm (18 ft. lbs.)





46. Install spark plugs.
Torque:
Spark Plugs: 20 Nm (15 ft. lbs.)





47. Install ignition coil and module assembly to camshaft cover.
Torque:
Ignition Coil-to-Camshaft Cover Bolts: 8 Nm (71 inch lbs.)





48. Install intake manifold onto intake manifold. Gasket may be reused if not damaged.
49. Install intake manifold.
50. Install intake manifold bolts and nuts. Tighten by starting from center bolt and working outward.
Torque:
Intake Manifold-to-Cylinder Head Bolts: 10 Nm (89 inch lbs.)
Torque:
Intake Manifold-to-Cylinder Head Nuts: 10 Nm (89 inch lbs.)





51. Attach wiring harness to brackets located under intake manifold.
52. Install oil indicator tube assembly.
Torque:
Oil Level Indicator Tube-to-Intake Manifold Bolt: 10 Nm (89 inch lbs.)





53. Install throttle body. Gasket may be reused if not damaged.
54. Install throttle body mounting bolts and nuts. Install throttle cable.
Torque:
Throttle Body Bolts: 10 Nm (89 inch lbs.)
Torque:
Throttle Body Nuts: 10 Nm (89 inch lbs.)
55. Position engine harness and install fasteners.
Torque:
Engine Harness Bracket Bolts: 10 Nm (89 inch lbs.)
56. Connect electrical connections.
57. Install camshaft cover ground strap.
Torque:
Camshaft Cover Ground Strap Fastener: 10 Nm (89 inch lbs.)





58. Attach cylinder head dogas hose onto coolant reservoir and attach to harness retainers.
Torque:
Degas Hose Bracket Bolt: 10 Nm (89 inch lbs.)
59. Attach hoses:
59.1. Upper radiator hose
59.2. Crankcase ventilation hose
59.3. Fuel pressure regulator hose
59.4. Brake booster hose
59.5. Evap purge hose





NOTICE: Plastic retainers must be replaced when fuel lines are disassembled. Install new retainer into female cavity. Care must be taken to ensure that locking tab is centered in window of female cavity. Firmly press female connection onto male end until a click is heard, then pull back to confirm engagement.

60. Install fuel lines. Ensure that lines are routed correctly
61. Clip lines into place and install fuel line bracket and bolt.
Torque:
Fuel Line Bolt: 10 Nm (89 inch lbs.)





62. Install exhaust flange onto exhaust flange.
63. Raise vehicle
64. Position manifold down pipe onto flange studs
65. Install flange nuts.
Torque:
Exhaust Manifold Pipe-to-Exhaust Manifold Nuts: 30 Nm (22 ft. lbs.)





66. Install exhaust downpipe to resonator bolts
Torque:
Exhaust Manifold Pipe-to-Resonator Bolts: 20 Nm (15 ft. lbs.)
67. Drain oil.
Torque:
Oil Drain Plug: 25 Nm (18 ft. lbs.)





68. Lower vehicle.
69. Install exhaust manifold heat shield and install bolts.
Torque:
Exhaust Manifold Heat Shield Bolts: 25 Nm (18 ft. lbs.)





70. Install air cleaner and inlet tube assembly.





71. Add engine oil.
72. Check level and install oil cap.





73. Fill coolant.
73.1. Add 50/50 Dex-Cool and water
73.2. Volume 6.9 quarts (auto trans) Volume 7.0 quarts (manual trans)
73.3. Install coolant surge cap
74. Connect battery cable.
75. Start vehicle and inspect for leaks.

NOTICE: After cylinder block, head or lifter replacement, it will be necessary to allow the engine to idle for three to five minutes. If lifters are noisy, warm the engine up at a low rpm (less than 2000). After the coolant temperature has reached approximately 85 degrees C (185 degrees F), cycle the engine rpm from idle to 3000 for approximately 10 minutes or drive the vehicle eight kilometers (five miles) to purge the air. If the air cannot be purged, the faulty lifter(s) will have to be replaced.
Lifters that are pumped up may cause PCM misfire codes to set. Continue to operate the engine until the lifters bleed down. Using the scan tool, clear codes and malfunction history.