Installation

SPECIAL TOOLS REQUIRED




INSTALLATION
1. Clean cylinder head, intake manifold, valve cover and cylinder block sealing surfaces as described under Disassembly and Assembly. If necessary, check cylinder head and cylinder block flatness.





2. Rotate crankshaft counterclockwise 45 degrees.

NOTE: This ensures that all pistons are below top of cylinder block deck face.

3. Inspect cylinder head face surface for scratches near coolant passage and combustion chambers.
4. Rotate camshaft to a stable position where valves do not extend below cylinder head face.





5. Position new head gaskets on cylinder block.
6. Install lower rear cylinder head bolts and retain in position with rubber bands or similar items.

CAUTION: Cylinder head bolts must be replaced with new bolts. They are torque-to-yield designed and cannot be reused.

7. Position LH cylinder head on cylinder head to block dowels.

NOTE: Take care not to score the surface of the cylinder head face.

8. Apply clean Super Premium SAE 5W30 Motor Oil XO-5W30-QSP to all head bolt spot-faces.
9. Remove rubber band from lower rear bolt and install nine remaining bolts. Hand-tighten.





10. Tighten LH cylinder head bolts in six steps as follows:
a. Tighten 10 bolts, in sequence, to 37-43 Nm (28-31 ft. lbs.).
b. Rotate 10 bolts, in sequence, 85-95 degrees.
c. Loosen 10 bolts, in sequence, a minimum of 360 degrees.
d. Tighten 10 bolts, in sequence, to 37-43 Nm (28-31 ft. lbs.)
e. Tighten 10 bolts, in sequence, 85-95 degrees.
f. Tighten 10 bolts, in sequence, an additional 85-95 decrees.

11. Position RH cylinder head on cylinder head to block dowel.
12. Apply clean Super Premium SAE 5W30 Motor Oil XO-5W30-QSP to all head bolt spot-faces.
13. Remove rubber band from lower rear bolt and install the nine remaining bolts. Hand-tighten.
14. Tighten RH cylinder head bolts in six steps as follows:
a. Tighten 10 bolts, in sequence, to 37-43 Nm (28-31 ft. lbs.).
b. Tighten 10 bolts, in sequence, 85-95 degrees.
c. Loosen 10 bolts, in sequence, a minimum of one full turn.
d. Tighten 10 bolts, in sequence, to 37-43 Nm (28-31 ft. lbs.).
e. Tighten 10 bolts, in sequence, 85-95 degrees.
f. Tighten 10 bolts, in sequence, an additional 85-95 degrees.

15. Position heater water hose on cylinder head and install one bolt and one nut. Tighten to 8-12 Nm (71-106 inch lbs.).
16. Install ground strap on RH cylinder head. Tighten retaining nut to 8-12 Nm (71-106 ft. lbs.).
17. Rotate camshafts using flats matched at center of camshaft until both are in time and install Cam Positioning Tool Adapters 303-413 and Cam Positioning Tool 303-380 on flats of camshaft. This will prevent the camshafts from rotating.





18. Rotate crankshaft clockwise 45 decrees.

CAUTION: Crankshaft must only be rotated in the clockwise direction and only as far as TDC.

NOTE: This will position crankshaft at TDC No 1.

19. Install timing chains.

CAUTION: Timing chain procedures must be followed exactly or damage to valves and/or pistons will result.

20. Install engine front cover.
21. Install valve covers.
22. Raise vehicle.
23. Position starter motor wiring harness to rear of cylinder head and install retainer.
24. Connect three way catalytic converters to RH and LH exhaust manifolds.
25. Position power steering pump to cylinder block and install retaining bolts. Tighten bolts to 20-30 Nm (15-22 ft. lbs.).
26. Lower vehicle.
27. Install intake manifold.
28. Connect battery ground cable.
29. Check and add clean Super Premium SAE 5W30 Motor Oil XO-5W30-QSP.
30. Start engine and inspect for leaks.