Cylinder Head - Installation

INSTALLATION






NOTE: 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 straight edge against the threads (3). 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.

1. Clean sealing surfaces of cylinder head and block Engine Gasket Surface Preparation.
2. Install new head gasket over locating dowels.
3. Install cylinder head to block, assuring head is properly positioned over locating dowels.





4. Lubricate bolt threads with clean engine oil and install bolts.
5. Tighten bolts in sequence shown for left head (2) and right head (1) using the following steps and torque values:
- Step 1: Bolts 1-8 to 48 Nm (35 ft. lbs.)
- Step 2: Bolts 1-8 to 75 Nm (55 ft. lbs.)
- Step 3: Bolts 1-8 to 75 Nm (55 ft. lbs.)
- Step 4: Bolts 1-8 to +90° Turn Do not use a torque wrench for this step.
- Step 5: Bolts 9-11 to 28 Nm (250 in. lbs.)

6. For left cylinder head installation:
- Install left exhaust manifold Exhaust Manifold - Installation
- Install power steering pump bracket and tighten bolts to 28 Nm (250 in. lbs.)
- Install engine oil dipstick tube and tighten bolt to 28 Nm (250 in. lbs.).
- Install power steering pump Power Steering Pump - Installation
- Install A/C compressor A/C Compressor - Installation

7. For right cylinder head Installation:
- Install right exhaust manifold Exhaust Manifold - Installation
- Install EGR valve (if equipped) Exhaust Gas Recirculation (EGR) Valve - Installation
- Install generator Generator - Installation
- Install cylinder head ground strap





8. Install all valvetrain components and camshafts Camshaft - Installation. Tighten camshaft bearing caps in sequence shown to 12 Nm (105 in. lbs.).





9. Install primary timing chain (7), guides (2, 5, 10) and sprockets (9) Timing Chain & Sprockets - Installation.





10. Install coolant outlet (3) Coolant Outlet Housing - Installation.





11. Install lower intake manifold Intake Manifold - Installation.
12. Install cylinder head covers Cylinder Head Cover(s) - Installation.
13. Connect camshaft position sensor (2) and coolant temperature sensor (1) connectors.
14. Install timing chain cover Engine Timing Cover(s) - Installation.
15. Install crankshaft vibration damper Vibration Damper - Installation.
16. Install upper intake manifold Intake Manifold - Installation.





17. Connect oil pressure sensor (1) connector.





18. Install accessory drive belt (5) Serpentine Accessory Drive Belt - Installation.
19. Fill cooling system Service and Repair.





20. Connect negative battery cable.
21. Start engine and check for leaks.