Cylinder Head - Installation

INSTALLATION - CYLINDER HEAD





NOTE: Ensure cylinder head bolt holes in the block are clean, dry (free of residual oil or coolant), and threads are not damaged.

NOTE: The Cylinder head bolts should be examined BEFORE reuse. If the threads are necked down, the bolts should 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 (2), the bolt should be replaced.






CAUTION: Always replace the variable valve timing filter screen (3) when servicing the head gasket or engine damage could result.

1. Replace the variable valve timing filter screen (3).




2. Place two pea size dots of RTV (1) on cylinder block as shown.




3. Position the new cylinder head gasket on engine block with the part number facing up. Ensure gasket is seated over the locating dowels in block.
4. Place two pea size dots of RTV (1) on cylinder head gasket as shown.

NOTE: The head must be installed within 15 minutes before the RTV skins.

5. Position cylinder head onto engine block.





NOTE: The front two cylinder head bolts do not have captured washers. The washers must be installed with the bevel up towards the bolt head.




6. Install washers (1) for the front two cylinder head bolts.




7. Before installing the bolts, the threads should be lightly coated with engine oil.
8. Install the cylinder head bolts and torque in the sequence shown above.
- First: All to 30 Nm (25 ft. lbs.)
- Second: All to 61 Nm (45 ft. lbs.)
- Third: All to 61 Nm (45 ft. lbs.)
- Fourth: All an additional 90�

CAUTION: Do not use a torque wrench for the Fourth step.

9. Clean excess RTV from timing chain cover sealing surface.
10. Install camshafts.




11. Install cylinder head cover.
12. Install maniverter/exhaust manifold to cylinder head. Torque fasteners to 34 Nm (25 lbs. ft.).
13. Install heat shields. Torque fasteners to 9 Nm (80 lbs.in.).
14. Install oxygen sensor in maniverter.
15. Install ground strap (1) at right rear of cylinder head.




16. Install coolant (2).
17. Install intake manifold.
18. Install intake manifold bolts and torque to 24 Nm (18 ft.lbs.).




19. Install upper radiator hose retaining bracket bolt (1).
20. Install timing chain.
21. Install timing chain cover.
22. Connect cam sensor wiring connector.
23. Install spark plugs and torque to 27 Nm (20 ft.lbs.).
24. Install ignition coils and torque to 8 Nm (70 in.lbs.).




25. Install power steering pump reservoir (2).
26. Install windshield washer reservoir (1).
27. Install coolant recovery reservoir (3)
28. Install exhaust pipe to manifold. Torque fasteners to 28 Nm (20 ft. lbs.).
29. Install accessory drive belts.
30. Connect engine coolant temperature sensor connector.




31. Connect upper radiator hose (3) to coolant adapter (2). Connect heater hoses (1) to thermostat housing.
32. Install heater tube support bracket to cylinder head.
33. Install fastener attaching dipstick tube to lower intake manifold.
34. Connect fuel supply line quick-connect at the fuel rail assembly.
35. Fill cooling system.




36. Connect negative cable to battery (3).
37. Install clean air hose (5) and air cleaner housing (1).
38. Install new oil filter and fill engine with oil.
39. Start engine and check for leaks.