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Cylinder Head - Installation






INSTALLATION - CYLINDER HEAD(S)

RIGHT CYLINDER HEAD





CAUTION: The cylinder head bolts are tightened using a torque plus angle procedure. The bolts must be examined BEFORE reuse. If the threads are necked down the bolts must be replaced.

1. Check cylinder head bolts for necking by holding a scale or straight edge against the threads. If all the threads do not contact the scale (2) the bolt must be replaced.






CAUTION: When cleaning cylinder head and cylinder block surfaces, DO NOT use a metal scraper because the surfaces could be cut or ground. Use ONLY a wooden or plastic scraper.

2. Clean sealing surfaces of cylinder head and blockEngine Gasket Surface Preparation.
3. Install camshaft (5) in cylinder head.

CAUTION: THE CYLINDER HEAD GASKETS ARE NOT INTERCHANGEABLE BETWEEN CYLINDER HEADS AND ARE CLEARLY MARKED RIGHT OR LEFT.

CAUTION: Ensure that the correct head gaskets are used and are oriented correctly on cylinder block.

4. Push camshaft (5) out of the back of the cylinder head approximately 3.5 inches. Install head gasket and cylinder head over locating dowels.

NOTE: Before installing the cylinder head bolts, lubricate the threads with clean engine oil.

5. Install and finger tighten eight head bolts (2).





6. Tighten the cylinder head bolts in the following sequence, using the 4 step torque-turn method. Tighten according to the following torque values:
- Step 1: All to 61 Nm (45 ft. lbs.)
- Step 2: All to 88 Nm (65 ft. lbs.)
- Step 3: All (again) to 88 Nm (65 ft. lbs.)
- Step 4: + 90° Turn Do not use a torque wrench for this step.

7. Bolt torque after 90° turn should be over 122 Nm (90 ft. lbs.) in the tightening direction. If not, replace the bolt.





8. Install three inner timing cover to cylinder head bolts (1). Tighten bolts to 54 Nm (40 ft. lbs.).






CAUTION: The camshaft sprockets are keyed and not interchangeable from side to side because of the camshaft position sensor pick-up.

9. Push the camshaft back into the cylinder head and install the camshaft sprocket (2).
10. Install NEW sprocket attaching bolt into place. The 255 mm (10 in.) bolt is to be installed in the left camshaft and the 213 mm (8 3/8 in.) bolt is to be installed into the right camshaft. Counterhold the camshaft sprocket (2) and tighten the camshaft sprocket bolt to 102 Nm (75 ft. lbs.) plus a 90° turn.





11. Install the camshaft thrust plate (1) and gasket (3). Tighten three bolts (2) to 28 Nm (250 in. lbs.).





12. Install new gasket between EGR solenoid/valve (2) and rear of cylinder head (1).
13. Position EGR solenoid/valve assembly to rear of cylinder head. Install and tighten two mounting bolts (6) to 8 Nm (80 in. lbs.).





14. Rotate the right camshaft gear (2) to align its timing mark (1). Verify that the left camshaft gear (7) timing mark (8) and crankshaft gear (10) timing mark (9) are still aligned.
15. Install the timing belt (4) starting at the crankshaft sprocket (10) going in a counterclockwise direction. Install the belt around the last sprocket. Maintain tension on the belt as it is positioned around the tensioner pulley (11).
16. Holding the tensioner pulley (11) against the belt, install the tensioner (12) into the housing and tighten two bolts to 28 Nm (250 in. lbs.). Each camshaft sprocket mark should remain aligned with the cover marks.
17. When tensioner is in place pull retaining pin to allow the tensioner to extend to the tensioner pulley bracket.
18. Rotate crankshaft sprocket two revolutions and check the timing marks on the camshafts and crankshaft. The marks should line up within their respective locations. If marks do not line up, repeat procedure.

NOTE: With the camshaft gears in these positions the lobes are in a neutral position (no load to the valve). This will allow the rocker arm shaft assembly to be tightened into position with little or no valve spring load on it.





19. Install the rocker arm and shaft assembly (2) and ten bolts making sure that the identification marks face toward the front of engine for left head and toward the rear of the engine for right head.





20. Tighten the ten rocker arm/shaft assembly bolts in sequence to 31 Nm (275 in. lbs.).





21. Clean cylinder head and cover mating surfaces. Inspect and replace gasket (1) and seals (2) as necessary Cylinder Head Cover(s) - Installation.
22. Install cylinder head cover and eight bolts. Tighten bolts to 12 Nm (105 in. lbs.).





23. Install the spark plugs. Tighten to 28 Nm (20 ft. lbs.) Spark Plug - Installation.
24. Install ignition coils (3) into cylinder head.
25. Install and tighten coil mounting bolts (2) to 6.7 Nm (60 in. lbs.).
26. Reposition engine wire harness and install retainers to cylinder head cover. Connect and lock electrical connectors to ignition coils (1), capacitor and EGR valve.





27. Reposition engine wire harness, connect and lock electrical connectors to PCM (1), body harness (3), A/C high pressure switch (2) and A/C compressor clutch.





28. Connect the front exhaust pipe to exhaust manifold (2). Tighten the fasteners (3) to 34 Nm (300 in. lbs.).





29. Reposition oil cooler hose retainer bracket (1) near timing belt tensioner and install bolt (2).





30. Install the front timing belt outer cover (1) and 14 bolts.
31. Tighten the timing cover bolts as follows:
- M6 bolts - 12 Nm (105 in. lbs.)
- M8 bolts - 28 Nm (250 in. lbs.)
- M10 bolts - 54 Nm (40 ft. lbs.)





32. Install crankshaft damper using Forcing Screw C-4685-C1 (2), with Nut and Thrust Bearing from 6792, and 6792-1 Installer (1).





33. Install crankshaft damper bolt (3). Tighten bolt to 95 Nm (70 ft. lbs.) while holding damper (1) with Damper Holding Fixture 9365 (2).





34. Install the accessory drive bracket (2). Tighten four bolts (1) and nut (3) to 54 Nm (40 ft. lbs.).





35. Install the stud (4) that secures the upper front of the compressor to the accessory drive belt bracket. Tighten the stud securely.
36. Install the lower bolt (3) and upper nut (5) that secures the front of the A/C compressor to the accessory drive bracket. Tighten fasteners to 28 Nm (21 ft. lbs.).





37. Position generator (1) to engine and install two mounting bolts (2) and (3). Tighten both bolts to 57 Nm (42 ft. lbs.).
38. Snap field wire connector into rear of generator.
39. Install B+ terminal and nut to generator mounting stud. Tighten nut to 13 Nm (115 in. lbs.)
40. Snap plastic protective cover to B+ terminal.





41. Install the power steering belt (1) Serpentine Accessory Drive Belt - Installation.





42. Install the accessory drive belt (7) Serpentine Accessory Drive Belt - Installation.





43. Use Adapter Pins 8346 in Spanner Wrench 6958 (1) to hold the pulley while installing the fan blade/viscous fan drive assembly. Tighten mounting nut to 50 Nm (37 ft. lbs.).





44. Install electric fan shroud with two screws (1). Tighten screws to 6 Nm (50 in. lbs.).
45. Connect and lock the electric fan connector (2).





46. Install transmission cooler line retainer to electric fan shroud with one screw (2).
47. Install radiator hose retainer (3) to electric fan shroud.





48. Install the coolant recovery/washer fluid reservoir assembly (1) with five screws. Connect two washer pump hoses, coolant recovery hose, and washer pump electrical connector.





49. Install lower intake manifold (3) and fuel rail (1) Intake Manifold - Installation.





50. Install the upper intake manifold, EGR tube, PCV, Purge and power brake booster vacuum hosesIntake Manifold - Installation.





51. Install and connect the air cleaner element housing (1) Air Cleaner - Installation.
52. Fill the coolant system Service and Repair.
53. Connect the negative battery cable. Tighten nut to 4.5 Nm (40 in. lbs.).

LEFT CYLINDER HEAD





CAUTION: The cylinder head bolts are tightened using a torque plus angle procedure. The bolts must be examined BEFORE reuse. If the threads are necked down the bolts must be replaced.

1. Check cylinder head bolts for necking by holding a scale or straight edge against the threads. If all the threads do not contact the scale (2) the bolt must be replaced.






CAUTION: When cleaning cylinder head and cylinder block surfaces, DO NOT use a metal scraper because the surfaces could be cut or ground. Use ONLY a wooden or plastic scraper.

2. Clean sealing surfaces of cylinder head and blockEngine Gasket Surface Preparation.
3. Install camshaft (5) in cylinder head.

CAUTION: THE CYLINDER HEAD GASKETS ARE NOT INTERCHANGEABLE BETWEEN CYLINDER HEADS AND ARE CLEARLY MARKED RIGHT OR LEFT.

CAUTION: Ensure that the correct head gaskets are used and are oriented correctly on cylinder block.

4. Push camshaft (5) out of the back of the cylinder head approximately 3.5 inches. Install head gasket and cylinder head over locating dowels.

NOTE: Before installing the cylinder head bolts, lubricate the threads with clean engine oil.

5. Install and finger tighten eight head bolts (2).





6. Tighten the cylinder head bolts in the following sequence, using the 4 step torque-turn method. Tighten according to the following torque values:
- Step 1: All to 61 Nm (45 ft. lbs.)
- Step 2: All to 88 Nm (65 ft. lbs.)
- Step 3: All (again) to 88 Nm (65 ft. lbs.)
- Step 4: + 90° Turn Do not use a torque wrench for this step.

7. Bolt torque after 90° turn should be over 122 Nm (90 ft. lbs.) in the tightening direction. If not, replace the bolt.





8. Install four inner timing cover to cylinder head bolts (1) and (2). Tighten bolts to 54 Nm (40 ft. lbs.).






CAUTION: The camshaft sprockets are keyed and not interchangeable from side to side because of the camshaft position sensor pick-up.

9. Push the camshaft back into the cylinder head and install the camshaft sprocket.
10. Install NEW sprocket attaching bolt into place. The 255 mm (10 in.) bolt is to be installed in the left camshaft and the 213 mm (8 3/8 in.) bolt is to be installed into the right camshaft. Counterhold the camshaft sprocket and tighten the camshaft sprocket bolt to 102 Nm (75 ft. lbs.) plus a 90° turn.





11. Install the camshaft thrust plate (1) and gasket (3). Tighten three bolts (2) to 28 Nm (250 in. lbs.).





12. Rotate the left camshaft gear (7) to align its timing mark (8). Verify that the right camshaft gear (2) timing mark (1) and crankshaft gear (10) timing mark (9) are still aligned.
13. Install the timing belt (4) starting at the crankshaft sprocket (10) going in a counterclockwise direction. Install the belt around the last sprocket. Maintain tension on the belt as it is positioned around the tensioner pulley (11).
14. Holding the tensioner pulley (11) against the belt, install the tensioner into the housing and tighten two bolts to 28 Nm (250 in. lbs.). Each camshaft sprocket mark should remain aligned with the cover marks.
15. When tensioner is in place pull retaining pin to allow the tensioner to extend to the tensioner pulley bracket.
16. Rotate crankshaft sprocket two revolutions and check the timing marks on the camshafts and crankshaft. The marks should line up within their respective locations. If marks do not line up, repeat procedure.

NOTE: With the camshaft gears in these positions the lobes are in a neutral position (no load to the valve). This will allow the rocker arm shaft assembly to be tightened into position with little or no valve spring load on it.





17. Install the rocker arm and shaft assembly (2) and ten bolts making sure that the identification marks face toward the front of engine for left head and toward the rear of the engine for right head.





18. Tighten the ten rocker arm/shaft assembly bolts in sequence to 31 Nm (275 in. lbs.).





19. Clean cylinder head and cover mating surfaces. Inspect and replace gasket (1) and seals (2) as necessary Cylinder Head Cover(s) - Installation.
20. Install cylinder head cover and eight bolts. Tighten bolts to 12 Nm (105 in. lbs.).





21. Install the spark plugs. Tighten to 28 Nm (20 ft. lbs.) Spark Plug - Installation.
22. Install ignition coil (3) into cylinder head.
23. Install and tighten coil mounting bolt (2) to 6.7 Nm (60 in. lbs.).
24. Reposition engine wire harness and install retainers to cylinder head cover. Connect and lock electrical connectors to ignition coils (1) and knock sensor.
25. Install dipstick tube and bolt.





26. Connect the front exhaust pipe to exhaust manifold (1). Tighten the fasteners (5) to 34 Nm (300 in. lbs.).





27. Reposition oil cooler hose retainer bracket (1) near timing belt tensioner and install bolt (2).





28. Install the front timing belt outer cover (1) and 14 bolts.
29. Tighten the timing cover bolts as follows:
- M6 bolts - 12 Nm (105 in. lbs.)
- M8 bolts - 28 Nm (250 in. lbs.)
- M10 bolts - 54 Nm (40 ft. lbs.)





30. Install crankshaft damper using Special Tools C-4685-C1 (5.9 in.) Bolt (2), with Nut and Thrust Bearing from 6792, and 6792-1 Installer (1).





31. Install crankshaft damper bolt (3). Tighten bolt to 95 Nm (70 ft. lbs.) while holding damper (1) with Special Tool 9365 (2).





32. Install the accessory drive bracket (2). Tighten four bolts (1) and nut (3) to 54 Nm (40 ft. lbs.).





33. Install the stud (4) that secures the upper front of the compressor to the accessory drive belt bracket. Tighten the stud securely.
34. Install the lower bolt (3) and upper nut (5) that secures the front of the A/C compressor to the accessory drive bracket. Tighten fasteners to 28 Nm (21 ft. lbs.).





35. Position generator (1) to engine and install two mounting bolts (2) and (3). Tighten both bolts to 57 Nm (42 ft. lbs.).
36. Snap field wire connector into rear of generator.
37. Install B+ terminal and nut to generator mounting stud. Tighten nut to 13 Nm (115 in. lbs.)
38. Snap plastic protective cover to B+ terminal.





39. Install the power steering belt (1) Serpentine Accessory Drive Belt - Installation.





40. Install the accessory drive belt (7) Serpentine Accessory Drive Belt - Installation.





41. Using Tool 6958, install the fan blade/viscous fan drive assembly. Tighten mounting nut to 50 Nm (37 ft. lbs.).





42. Install electric fan shroud with two screws (1). Tighten screws to 6 Nm (50 in. lbs.).
43. Connect and lock the electric fan connector (2).





44. Install transmission cooler line retainer to electric fan shroud with one screw (2).
45. Install radiator hose retainer (3) to electric fan shroud.





46. Install the coolant recovery/washer fluid reservoir assembly (1) with five screws. Connect two washer pump hoses, coolant recovery hose, and washer pump connector.





47. Install lower intake manifold (3) and fuel rail (1) Intake Manifold - Installation.





48. Install the upper intake manifold, support brackets, EGR tube, PCV, Purge and power brake booster vacuum hoses Intake Manifold - Installation.





49. Install and connect the air cleaner element housing (1) Air Cleaner - Installation.
50. Fill the coolant system Service and Repair.
51. Connect the negative battery cable. Tighten nut to 4.5 Nm (40 in. lbs.).

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