Cylinder Head - Installation

INSTALLATION





1. Position the cylinder head gasket and the cylinder head on the engine block dowels.

NOTE: Measure and inspect cylinder head bolts before reuse. Do not reuse bolts that exceed 144 mm (1) in length.

NOTE: Apply a thin coat of lubricant to head bolt threads before installing.





2. Install, but do not tighten the cylinder head bolts (1).




3. Use the tightening sequence chart to tighten the cylinder head bolts.

NOTE: Bolts numbered 9 and 10 are timing chain cover bolts. They should be tightened after the cylinder head bolts are tightened.

4. Tighten the cylinder head bolts in four stages.
- Stage one, 10 Nm (7 ft. lbs.)
- Stage two, 30 Nm (22 ft. lbs.)
- Stage three, Rotate bolts 90° clockwise.
- Stage four Rotate bolts 90° clockwise.
- Tighten bolts 9 and 10 to 20 Nm (7-15 ft. lbs.).

5. Using Special Tools 9104 and 9105 Camshaft Locating Plates, lock the camshafts.




6. Install the camshaft sprockets and bolts (1).
7. Tighten the camshaft sprocket bolts in two stages.
- Stage one, 50 Nm (37 ft. lbs).
- Stage two, Rotate bolts 90° clockwise.





8. Remove the cable tie (1).




9. Install the timing chain tensioner (1). Tighten the timing chain tensioner to 80 Nm (60 ft. lbs.).
10. Remove Special Tools 9104 and 9105 Camshaft Locating Plates.
11. Check for a crankshaft position of 40° ATDC Description and Operation.
12. Connect the exhaust system at the manifold flanges and tighten the exhaust flange bolts to 20 Nm (15 ft. lbs.).
13. Install the cylinder head covers Cylinder Head Cover - Installation.
14. Install the intake manifold Intake Manifold - Installation.
15. Install and connect the ignition coils Ignition Coil - Installation.
16. Install the accessory drive belt Accessory Drive Belt - Installation.
17. Install and connect the radiator fan with the radiator Radiator - Installation.




18. Install the camshaft position sensor and bolt (2). Connect the camshaft position sensor harness connector (1). Tighten the bolt to 10 Nm (7 ft. lbs.).
19. Install the engine air cleaner housing.
20. Fill the cooling system Service and Repair.
21. Fill the engine oil Service and Repair.
22. Start the engine and check for leaks during warm up.
23. Recheck all fluid levels.