Installation
Cylinder Head
NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, can cause engine failure.
Installation
Both sides
1. Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign material is removed.
2. Position the cylinder head gaskets on the block.
RH side
3. NOTE: To avoid damage to the timing chain cassette, an assistant will be required to help position the cylinder head in the vehicle.
NOTE: New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused.
Position the RH cylinder head. Install 8 new M12 bolts and tighten in the sequence shown in 2 stages.
- Stage 1: Tighten to 12 Nm (106 lb-in).
- Stage 2: Tighten to 25 Nm (18 lb-ft).
4. Install 2 new M8 bolts.
- Tighten to 32 Nm (24 lb-ft).
5. Tighten the 8 M12 bolts in the sequence shown in 2 stages.
- Stage 1: Tighten 90 degrees.
- Stage 2: Tighten an additional 90 degrees.
6. NOTE: The camshaft gear must turn freely on the camshaft. Do not tighten the bolt at this time.
NOTE: The right-hand camshaft sprocket bolt is a left-hand threaded bolt.
Remove the rubber band, position the camshaft sprocket and chain. Loosely install the bolt.
7. Install the RH side cassette bolt.
- Tighten to 12 Nm (106 lb-in).
LH side
8. NOTE: To avoid damage to the timing chain cassette, an assistant will be required to help position the cylinder head in the vehicle.
NOTE: New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused.
Position the LH cylinder head. Install 8 new M12 bolts and tighten in the sequence shown in 2 stages.
- Stage 1: Tighten to 12 Nm (106 lb-in).
- Stage 2: Tighten to 25 Nm (18 lb-ft).
9. Install 2 new M8 bolts.
- Tighten to 32 Nm (24 lb-ft).
10. Tighten the 8 M12 bolts in the sequence shown in 2 stages.
- Stage 1: Tighten 90 degrees.
- Stage 2: Tighten an additional 90 degrees.
11. NOTE: The camshaft gear must turn freely on the camshaft. Do not tighten the bolt at this time.
Remove the rubber band, position the camshaft sprocket and chain. Loosely install the bolt.
12. Install the LH side cassette bolt.
- Tighten to 19 Nm (168 lb-in).
Both sides
13. NOTE: LH side shown, RH side similar.
Install the 12 exhaust manifold studs.
- Tighten to 12 Nm (106 lb-in).
14. NOTE: LH side shown, RH side similar.
Position new gaskets and the exhaust manifolds. Install the 12 new nuts.
- Tighten to 23 Nm (17 lb-ft).
15. NOTE: Apply dielectric compound to the inside of the spark plug wire boots.
Connect the 6 spark plug wires to the spark plugs.
16. NOTE: LH side shown, RH side similar.
Install the 4 new catalytic converter-to-exhaust manifold nuts.
- Tighten to 45 Nm (33 lb-ft).
17. NOTE: Lubricate the new O-ring seals with clean engine oil.
Install the 6 fuel injectors.
- Install new O-ring seals on the injectors.
- Install the injectors.
18. Position the fuel rail and injectors and install the 4 bolts.
- Tighten to 23 Nm (17 lb-ft).
19. NOTE: The LH and RH camshafts must be retimed when either camshaft is disturbed.
Turn the crankshaft clockwise to position the No. 1 cylinder at Top Dead Center (TDC).
20. NOTICE: Do not rotate the engine counterclockwise. Rotating the engine counterclockwise will result in damage to the damper crank sensor speed wheel and incorrect timing to the engine.
NOTE: The Crankshaft TDC Timing Tool must be installed on the damper and should contact the engine block, this positions the engine at TDC.
Install the Crankshaft TDC Timing Tool.
21. NOTE: Leave the top 2 Camshaft Sprocket Holding Tool clamp bolts loose.
Install the Camshaft Sprocket Holding Tool and Adapter on the rear of the RH cylinder head.
22. NOTE: The camshaft timing slots are off-center.
Position the camshaft timing slots below the centerline of the camshaft to correctly fit the Camshaft Holding Tool and Adapter, and install the Camshaft Holding Tool and Adapters on the front of the RH cylinder head.
23. Install the Timing Chain Tensioner.
24. Tighten the 2 top Camshaft Sprocket Holding Tool bolts to 10 Nm (89 lb-in).
25. NOTE: The RH camshaft sprocket bolt is a LH-threaded bolt.
Using the Torque Wrench Extension with the Camshaft Sprocket Nut Socket 303-565, tighten the camshaft bolt to 85 Nm (63 lb-ft).
26. Install a new washer and the RH camshaft tensioner.
- Tighten to 44 Nm (32 lb-ft).
27. NOTE: Leave the top 2 Camshaft Sprocket Holding Tool clamp bolts loose.
Install the Camshaft Sprocket Holding Tool and Adapter on the front of the LH cylinder head.
28. NOTE: The camshaft timing slots are off-center.
Position the camshaft timing slots below the centerline of the camshaft to correctly fit the Adapters, and install the Camshaft Holding Tool and Adapter on the rear of the LH cylinder head.
29. Install the Timing Chain Tensioner.
30. Tighten the bolts.
1. Tighten the Camshaft Sprocket Holding Tool top 2 bolts to 10 Nm (89 lb-in).
2. Tighten the camshaft sprocket bolt to 85 Nm (63 lb-ft).
31. Install a new washer and the LH camshaft tensioner.
- Tighten to 44 Nm (32 lb-ft).
LH side
32. Position the ground strap and install the bolt.
- Tighten to 40 Nm (30 lb-ft).
- Attach the wiring harness retainer to the backside of the cylinder head.
33. Position the starter motor wiring retainer bracket and install the bolt.
- Tighten to 40 Nm (30 lb-ft).
34. Position the FEAD bracket and A/C compressor. Install the 3 bolts and the nut.
- Tighten to 48 Nm (35 lb-ft).
35. Position the power steering pump and install the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).
36. Position the power steering pump pulley and install the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).
37. Attach PSP tube bracket to the crossmember and install the bolt.
- Tighten to 11 Nm (97 lb-in).
38. Attach the power steering supply hose bracket to the FEAD bracket and install the bolt.
- Tighten to 11 Nm (97 lb-in).
39. Position the ground strap and install the stud bolt.
- Tighten to 10 Nm (89 lb-in).
40. Install the oil level indicator tube and bolt.
- Tighten to 11 Nm (97 lb-in).
RH side
41. NOTE: Inspect the O-ring seal. Install a new O-ring seal if necessary.
Position the thermostat housing and install the 3 bolts.
- Tighten to 11 Nm (97 lb-in).
42. Position the coolant bypass hose clamp and connect the ECT sensor electrical connector.
43. Install the upper radiator hose.
44. Connect the heater hose to the thermostat housing.
45. Position the generator mounting bracket assembly and install the 2 bolts and the nut.
- Tighten to 47 Nm (35 lb-ft).
46. Install the accessory drive belt tensioner and bolt.
- Tighten to 47 Nm (35 lb-ft).
47. Connect the generator electrical connector. Position the B+ terminal and install the nut.
- Tighten to 8 Nm (71 lb-in).
- Attach the pin-type retainer.
48. Install the 2 coolant tube bracket bolts.
- Tighten the M12 bolt to 34 Nm (25 lb-ft).
- Tighten the M8 bolt to 23 Nm (17 lb-ft).
Both sides
49. Rotate the accessory drive belt tensioner counterclockwise and install the accessory drive belt.
50. Install the hydraulic lash adjusters. For additional information, refer to Hydraulic Lash Adjuster Hydraulic Lash Adjuster.
51. Install the intake manifold. For additional information, refer to Intake Manifold Service and Repair.
52. Fill and bleed the engine cooling system.