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 block Engine 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.

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

4. Insert the front four cylinder head bolts (2) into the cylinder head. Pull the bolts up to the top of their travel and retain with rubber bands (3).
5. Push camshaft (5) out of the back of the cylinder head approximately 3.5 inches. Install head gasket and cylinder head over locating dowels.
6. Install and finger tighten eight head bolts (2).





7. 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.

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





9. Install the 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.

10. Push the camshaft back into the cylinder head and install the camshaft sprocket.
11. 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.





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





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





15. 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.
16. 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).
17. 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.
18. When tensioner is in place pull retaining pin to allow the tensioner to extend to the tensioner pulley bracket.
19. 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.





20. 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.





21. Tighten the ten rocker arm/shaft assembly bolts in sequence to 31 Nm (275 in. lbs.).
22. Install the right cylinder head cover Cylinder Head Cover(s) - Installation.
23. Install the right valve cover to cylinder head ground strap.





24. Install the front timing belt outer covers.
25. 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.)





26. Install the power steering reservoir (1). Tighten mounting nut to 12 Nm (9 ft. lbs.).





27. Install the power steering pump (2) Power Steering Pump Pulley - Installation





28. Install the accessory drive belt idler pulley (2). Tighten bolt to 28 Nm (250 in. lbs.).





29. Install the upper engine mount Engine Mount Insulator - Installation.





30. Install the right exhaust maniverter (2) Exhaust Manifold - Installation.





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





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





33. Install the accessory drive belt tensioner (1). Tighten bolt to 61 Nm (45 ft. lbs.).





34. Install the accessory drive belt (2) Serpentine Accessory Drive Belt - Installation.





35. Install the right inner splash shield (1) Splash Shield - Installation
36. Install the right front tire Tires and Wheels - Installation
37. Lower the vehicle.





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





39. Install the upper intake manifold (1) including EGR tube Intake Manifold - Installation.





40. Install the air cleaner element housing Air Cleaner Body - Installation.
41. Install the engine cover.
42. Fill the coolant system Service and Repair
43. 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 block Engine 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.

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

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.
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. Install the left cylinder head cover Cylinder Head Cover(s) - Installation.
20. Install the left valve cover to cylinder head ground strap.





21. Install the front timing belt outer covers.
22. 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.)





23. Install the power steering reservoir (1). Tighten mounting nut to 12 Nm (9 ft. lbs.).





24. Install the power steering pump (2) Power Steering Pump Pulley - Installation





25. Install the accessory drive belt idler pulley (2). Tighten bolt to 28 Nm (250 in. lbs.).





26. Install the upper engine mount Engine Mount Insulator - Installation.





27. Install the left exhaust maniverter Exhaust Manifold - Installation.





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





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





30. Install the accessory drive belt tensioner (1). Tighten bolt to 61 Nm (45 ft. lbs.).





31. Install the accessory drive belt (2) Serpentine Accessory Drive Belt - Installation.





32. Install the right inner splash shield (1) Splash Shield - Installation
33. Install the right front tire Tires and Wheels - Installation
34. Lower the vehicle.





35. Install the coolant recovery container (1) and radiator fan assembly (2) Cooling Fan - Installation.
.




36. Install the radiator crossmember (2) Radiator Crossmember - Installation.





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





38. Install the upper intake manifold (1) including EGR tube Intake Manifold - Installation.





39. Install the air cleaner element housing Air Cleaner Body - Installation.
40. Install the engine cover.
41. Fill the coolant system Service and Repair
42. Connect the negative battery cable. Tighten nut to 4.5 Nm (40 in. lbs.).