Right Cylinder Head

RIGHT

Special Tools:











CAUTION: The magnetic timing wheels (1) must not come in contact with magnets (pickup tools, trays, etc.) or any other strong magnetic field. This will destroy the timing wheels ability to correctly relay camshaft position to the camshaft position sensor.





1. If removed, install the ignition coil capacitor (1) with an M6 bolt (2) tightened to 10 Nm (89 in. lbs.).






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.

NOTE: Typical cylinder head bolt shown.

2. Check the 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.

3. Clean and prepare the gasket sealing surfaces of the cylinder head and block Engine Gasket Surface Preparation.

CAUTION: Non-compressible debris such as oil, coolant or RTV sealants that are not removed from bolt holes can cause the aluminum casting to crack when tightening the bolts.

4. Clean out the cylinder head bolt holes in the engine block.

WARNING: The multi-layered steel head gaskets have very sharp edges that could cause personal injury if not handled carefully.

CAUTION: The cylinder head gaskets are not interchangeable between the left and right cylinder heads and are clearly marked (3) with "R" for right and "L" for left.

5. Position the new cylinder head gasket (1) on the locating dowels (2).





6. Position the cylinder head onto the cylinder block. Make sure the cylinder head seats fully over the locating dowels.

NOTE: Do not apply any additional oil to the bolt threads.

7. Install the eight cylinder head bolts finger tight.
8. Tighten the cylinder head bolts in the sequence shown, following this 9 step torque plus angle method. Tighten according to the following torque values:
- Step 1: All to 30 Nm (22 ft. lbs.)
- Step 2: All to 45 Nm (33 ft. lbs.)
- Step 3: All + 75° Turn Do not use a torque wrench for this step.
- Step 4: All + 50° Turn Do not use a torque wrench for this step.
- Step 5: Loosen all fasteners in reverse of sequence shown
- Step 6: All to 30 Nm (22 ft. lbs.)
- Step 7: All to 45 Nm (33 ft. lbs.)
- Step 8: All + 70° Turn Do not use a torque wrench for this step.
- Step 9: All + 70° Turn Do not use a torque wrench for this step.





NOTE: If the hydraulic lifters are being reused, reassemble them into their original locations.

9. If removed, install the hydraulic lifters . Hydraulic Lifter - Removal

NOTE: If the rocker arms are being reused, reassemble them into their original locations.

10. Install the rocker arms and camshafts Camshaft - Installation.

CAUTION: Do not rotate the camshafts more than a few degrees independently of the crankshaft. Valve to piston contact could occur resulting in possible valve damage. If the camshafts need to be rotated more than a few degrees, first move the pistons away from the cylinder heads by rotating the crankshaft counterclockwise to a position 30° before-top-dead-center. Once the camshafts are returned to their top-dead-center position, rotate the crankshaft clockwise to return the crankshaft to top-dead-center.

11. Verify that the camshafts are set at TDC by positioning the alignment holes (1) vertically.





12. Install the right cam chain guide (1) with three bolts (2). Tighten the T30 bolts (2) to 12 Nm (106 in. lbs.).
13. Install the right cam chain tensioner (3) to the engine block with two bolts (4). Tighten the T30 bolts (4) to 12 Nm (106 in. lbs.).
14. Reset the right cam chain tensioner (3) by pushing back the tensioner piston and installing Tensioner Pin (5).
15. Install the right tensioner arm (6).






CAUTION: Always reinstall timing chains so that they maintain the same direction of rotation. Inverting a previously run chain on a previously run sprocket will result in excessive wear to both the chain and sprocket.

16. Press the right exhaust cam phaser onto the exhaust camshaft. Install and hand tighten the oil control valve.
17. Drape the right side cam chain over the right exhaust cam phaser and onto the idler sprocket (1) so that the dimple (2) is aligned with the plated link (3) on the cam chain.





18. While maintaining this alignment, route the cam chain around the exhaust and intake cam phasers so that the plated links are aligned with the phaser timing marks (1). Position the right side cam phasers so that the arrows (3) point away from each other and the scribe lines (4) are parallel to the valve cover sealing surface (6). Press the intake cam phaser onto the intake cam, install and hand tighten the oil control valve (2).

NOTE: Minor rotation of a camshaft (a few degrees) may be required to install the camshaft phaser or phaser lock.

19. Install the RH Camshaft Phaser Lock (5) and tighten the oil control valves (2) and (7) to 150 Nm (110 ft. lbs.).





20. Remove the RH Camshaft Phaser Lock.
21. Remove the Tensioner Pin (6) from the RH cam chain tensioner.
22. Rotate the crankshaft clockwise two complete revolutions stopping when the dimple (4) on the crankshaft is aligned the with the block/bearing cap junction (5).
23. While maintaining this alignment, verify that the arrows on the left side cam phasers (2) point toward each other and are parallel to the valve cover sealing surface (3) and that the right side cam phaser arrows (7) point away from each other and the scribe lines (9) are parallel to the valve cover sealing surface (8).





24. There should be 12 chain pins (2) between the exhaust cam phaser triangle marking (1) and the intake cam phaser circle marking (3).
25. If the engine timing is not correct, repeat this procedure.
26. Install the engine timing cover, crankshaft vibration damper, upper and lower oil pans and cylinder head covers Engine Timing Cover(s) - Installation.






NOTE: The left side ignition coils are shown, the right side ignition coils are similar.

27. Install the spark plugs and tighten to 18 Nm (13 ft. lbs.) . Spark Plug - Installation
28. Install the ignition coils (2) . Ignition Coil - Installation





29. Position the upper intake manifold support bracket (2) and install the retaining stud (3) finger tight.





30. Install the heater core supply tube (1) with one bolt (2) tightened to 12 Nm (106 in. lbs.).





31. Position the oil level indicator (2), install the retaining bolt (1) and tighten to 12 Nm (106 in. lbs.).





32. Install the generator (1) Generator - Installation.
33. Rotate the accessory drive belt tensioner (7) counterclockwise until it contacts the stop and install the accessory drive belt (3), then slowly rotate the tensioner into position.





34. Install the right down pipe (2) onto the partially installed lower flange bolts (3).
35. Install the upper down pipe flange bolts (1) and tighten all M8 bolts to 23 Nm (17 ft. lbs.).
36. Connect the right upstream oxygen sensor connectors (4) to the main wire harness.





37. Install the upper and lower intake manifolds Intake Manifold - Installation.





38. Connect the electrical connector at the Camshaft Position Sensor (CMP) (6).
39. Connect the electrical connector at the Electronic Throttle Control (ETC ) (5).
40. Connect the electrical connector at the Manifold Absolute Pressure (MAP) Sensor (4).
41. Connect the brake booster vacuum hose (3).
42. Connect the PCV hose to the PCV valve (1) and to the intake manifold (2).





43. Connect the EVAP purge solenoid vacuum line (4) to the intake manifold.
44. Connect the vacuum line (3) to the EVAP purge solenoid (1).





45. Raise and support the vehicle Maintenance.
46. If removed, install the oil filter.
47. Position the belly pan and install the retainers (1).
48. Lower the vehicle.





49. Position the air cleaner housing (3) into the vehicle.
50. Install the air cleaner housing retaining bolt (2) and tighten to 12 Nm (9 ft. lbs.).
51. Connect the fresh air makeup hose (1) to the air cleaner housing.





52. Position the air inlet hose assembly (5) onto the throttle body and the air cleaner housing.
53. Secure the air inlet hose assembly retaining grommet onto the ball stud (4).
54. Tighten the clamp at the air cleaner housing (3) to 5 Nm (44 in. lbs.).
55. Tighten the clamp (2) at the throttle body to 5 Nm (44 in. lbs.).
56. Connect the Inlet Air Temperature (IAT) sensor electrical connector (1).





57. Fill the crankcase with the specified type and amount of engine oil .
58. Fill the cooling system with the specified type and amount of engine coolant Service and Repair.
59. Position the engine cover (1) and secure the retaining grommets onto the ball studs.





60. Connect the negative battery cable and tighten nut to 5 Nm (45 in. lbs.).
61. Run the engine until it reaches normal operating temperature and check for leaks.

NOTE: The Cam/Crank Variation Relearn procedure must be performed using the scan tool anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components.