Cylinder Head - Installation

INSTALLATION - CYLINDER HEAD





NOTE: The Cylinder head bolts should be examined BEFORE reuse. If the threads are necked down, the bolts should be replaced.

Necking (1) can be checked by holding a scale or straight edge against the threads. If all the threads do not contact the scale (2) , the bolt should be replaced.





NOTE: Cylinder head should be cleaned and inspected prior to replacement.

1. Position the new cylinder head gasket on engine block with the part number (1) facing up. Ensure gasket is seated over the locating dowels in block.
2. Position cylinder head onto engine block.
3. Before installing the bolts, the threads should be lightly coated with engine oil.




4. Tighten the cylinder head bolts in the sequence shown. Using the 4 step torque-turn method, tighten according to the following values:
- First: All to 34 Nm (25 ft. lbs.)
- Second: All to 82 Nm (60 ft. lbs.)
- Third: All to 82 Nm (60 ft. lbs.)

CAUTION: Do not use a torque wrench for the Fourth step.

- Fourth: Turn all bolts an additional 1/4 Turn





5. Install rocker arms
6. Install camshafts (3)Camshaft - Installation.




7. Install cylinder head cover Cylinder Head Cover - Installation.




8. Install rear timing belt cover and tighten fasteners (1,2)Timing Cover - Installation.
9. Install timing belt tensioner.
10. Install camshaft sprockets and timing beltTiming Belt & Sprockets - Installation.




11. Connect cam sensor wiring connector (3).
12. Install ignition coil and plug wires. Connect ignition coil wiring connector.




13. Non-Turbo equipped vehicles: Install power steering pump bracket (3) and reservoir ( 1) to cylinder head.




14. Turbocharger equipped vehicles: .
- Install coolant return line (2).
- Install coolant supply line (3).
- Install oil supply line (1).
- Install oil return tube (4).





15. Turbocharger equipped vehicles:
- Install elbow (3)
- Install turbocharger support bracket (2).
- Install elbow support bracket (4).
- Install turbocharger heat shields (1).

16. Install exhaust pipe to manifold. Tighten fasteners to 28 Nm (20 ft. lbs.).
17. Install accessory drive beltsAccessory Drive Belt - Installation.




18. Connect engine coolant temperature sensor connector.
19. Connect upper radiator hose to coolant outlet (2). Connect heater hoses to thermostat housing.
20. Install heater tube support bracket to cylinder head.




21. Turbocharger equipped vehicles: Install lower intake manifold support bracket (3).




22. Install fastener (3) attaching dipstick tube (1) to lower intake manifold.




23. Connect fuel supply line (1) quick-connect at the fuel rail assemblyService and Repair.
24. Install upper intake manifoldIntake Manifold - Installation.
25. Remove radiator pressure cap (3) and fill the cooling system.
26. Connect negative cable to battery.




27. Install clean air hose (1) and air cleaner housing (2).