Right Cylinder Head

INSTALLATION - CYLINDER HEAD(S)

RIGHT CYLINDER HEAD

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

1. Clean sealing surfaces of cylinder head and block Engine Gasket Surface Preparation.




CAUTION: The cylinder head gaskets are not interchangeable between cylinder heads and are clearly marked right or left.

2. Install head gasket over locating dowels. Ensure the gasket is installed on the correct side of engine.




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..

Necking can be checked by holding a scale or straight edge against the threads. If all the threads do not contact the scale the bolt must be replaced.





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

3. Insert the front four cylinder head bolts into the cylinder head. Pull the bolts up to the top of their travel and retain with rubber bands.
4. Install the cylinder head over locating dowels and finger tighten the head bolts.




5. Tighten the cylinder head bolts in the sequence shown.
6. 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 the inner timing cover to cylinder head bolts. Tighten bolts to 54 Nm (40 lbs.ft.).




9. Apply light coat of clean engine oil to the camshaft oil seal lip and Special Tool 6788 Seal Protector Sleeve.
10. Install oil seal Special Tool 6788 Seal Protector Sleeve onto the camshaft.
11. NOTE: When installing the camshaft (1) into the cylinder head (4), you must insert the seal protector (2) through the camshaft seal (3) until the camshaft seats, then remove Special Tool 6788 (2) from the camshaft.




12. Install camshaft sprocket. Counterhold the camshaft sprocket gear and tighten the camshaft sprocket bolt to 102 Nm plus a 1/4 turn (75 lbs. ft. plus a 1/4 turn) Timing Belt & Sprockets - Installation.




13. Install the rear camshaft thrust plate (1).




14. Rotate the camshaft gear to the timing mark (1) and verify the left camshaft gear (1) and crankshaft gear timing marks (2) are aligned.
15. Install the timing belt and tensioner Timing Belt & Sprockets - Installation.




16. Install the timing belt outer cover Timing Cover - Installation.
17. Install the power steering reservoir.




18. Install the vibration damper Vibration Damper - Installation.
19. Install the upper engine mount Front Engine Mount.
20. Install the accessory drive belt tensioner.
21. Install the lower accessory drive belt idler pulley (6).
22. Install the right exhaust manifold Exhaust Manifold - Installation.
23. Raise the vehicle.
24. Install the exhaust cross over pipe Exhaust Manifold - Installation.
25. Install the catalytic converter and exhaust system.
26. Connect both oxygen sensors.
27. Lower the vehicle.




28. Install the right rocker arm assembly (2).
29. Install the right cylinder head cover and ground strap.




30. Install the EGR valve (1) and tube assembly.




31. Install lower intake manifold (1) Intake Manifold - Installation.




32. Install the fuel rail.Fuel Rail - Removal.




33. Install the upper intake manifold (2) Intake Manifold - Installation.




34. Connect the fuel line (1) to the fuel rail Fuel Rail - Installation.




35. Install the air cleaner housing Air Cleaner Housing - Installation.
36. Install the engine cover.
37. Fill the coolant system.




38. Connect the negative battery cable (1).