11. Cylinder Head Assemble

Cylinder Head Assemble

Tools Required
* J 8062 Valve Spring Compressor - Head Off
* KM-653-A Adapter

Assembly Procedure

Caution: Refer to Safety Glasses Caution Safety Glasses Caution.




1. Coat the valve stems with engine oil.
2. Insert the valves in the cylinder head in their original positions.
3. Insert the valve spring seats.

Caution: Refer to Compressed Valve Spring Caution Technician Safety Information.

4. Push the accompanying assembly sleeve onto the valve stem.
5. Insert the new valve stem seat.
6. Carefully drive the valve stem seal onto the stop with light taps.
7. Install the valve springs in their original positions.
8. Install the valve springs caps.




9. Compress the valve springs with the J 8062 (1) and KM-653-A (2).
10. Install the valve retainers.
11. Remove the J 8062 (1) and KM-653-A (2).




12. Lubricate the valve lash adjusters with engine oil.
13. Install the valve lash adjusters.




14. Install the intake camshaft.
15. Install the intake camshaft bearing caps in their original positions.
16. Install the exhaust camshaft.
17. Install the exhaust camshaft bearing caps in their original positions.
18. Install the camshaft bearing cap bolts.

Notice: Refer to Fastener Notice Fastener Notice.

19. Tighten the camshaft bearing cap bolts gradually and in the sequence shown for each camshaft cap.

Tighten the camshaft bearing cap bolts to 8 Nm (71 lb in).




20. Install the spark plugs.

Tighten the spark plugs to 20 Nm (15 lb ft).

21. Install the ignition coil and exhaust gas recirculation (EGR) mounting bracket and bolt.

Tighten the ignition coil and EGR mounting bracket bolts to 25 Nm (18 lb ft).

22. Install the ignition coil and EGR.

Tighten the ignition coil and EGR to 25 Nm (18 lb ft).




23. Install the intake manifold studs.
24. Install the intake manifold gasket.
25. Install the intake manifold.
26. Install the intake manifold retaining nuts and retaining bolts in the sequence shown.

Tighten the intake manifold retaining nuts and retaining bolts to 22 Nm (16 lb ft).




27. Install the fuel rail assembly. Refer to Fuel Rail Assembly Replacement Service and Repair.
28. Install the thermostat housing assembly.
29. Install the thermostat housing mounting bolts.

Tighten the thermostat housing mounting bolts to 15 Nm (11 lb ft).

30. Install the coolant bypass housing bolts.

Tighten the coolant bypass housing bolts to 15 Nm (11 lb ft).




31. Install the exhaust manifold studs.
32. Install the exhaust manifold gasket.
33. Install the exhaust manifold.
34. Install the exhaust manifold retaining nuts in the sequence shown.

Tighten the exhaust manifold retaining nuts to 22 Nm (16 lb ft).

35. Install the exhaust manifold heat shield.
36. Install the exhaust manifold heat shield bolts.

Tighten the exhaust manifold heat shield bolts to 8 Nm (71 lb in).

37. Install the cylinder head with the intake manifold and the exhaust manifold attached. Refer to Cylinder Head Replacement Service and Repair.