Part 1
Cylinder Head
Installation
All cylinder heads
1. Verify the crankshaft keyway is in the 9 o'clock position.
2. NOTICE: Make sure all coolant residue and foreign material are cleaned from the block surface and cylinder bore. Failure to follow these instructions may result in engine damage.
NOTICE: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry. Failure to follow these instructions may result in future oil leakage.
NOTICE: The cylinder head bolts must be discarded and new bolts installed. They are a tighten-to-yield design and cannot be reused.
NOTE: Do not turn the crankshaft until instructed to do so.
NOTE: LH shown, RH similar.
Using the Cylinder Head Alignment Pins, position the cylinder head gaskets and cylinder heads over the dowels and install the cylinder head bolts loosely.
RH cylinder head
3. Tighten the new RH cylinder head bolts in 4 stages in the sequence shown.
- Stage 1: Tighten to 25 Nm (18 lb-ft).
- Stage 2: Tighten to 40 Nm (30 lb-ft).
- Stage 3: Tighten an additional 90 degrees.
- Stage 4: Tighten an additional 90 degrees.
4. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraper to clean the sealing surfaces.
Clean the exhaust manifold mating surface of the cylinder head with metal surface prep. Follow the directions on the packaging.
5. Install 8 new RH exhaust manifold studs.
- Tighten to 25 Nm (18 lb-ft).
6. NOTE: The tightening specification differs between early build (coarse thread) and late build (fine thread) exhaust manifold nuts.
Install new gaskets, the RH exhaust manifold and 8 new nuts.
- Tighten early build (coarse thread) nuts in the sequence shown in 2 stages.
- Stage 1: Tighten to 28 Nm (21 lb-ft).
- Stage 2: Tighten to 37 Nm (27 lb-ft).
- Tighten late build (fine thread) nuts in the sequence shown in 2 stages.
- Stage 1: Tighten to 24 Nm (18 lb-ft).
- Stage 2: Tighten to 32 Nm (24 lb-ft).
7. Install the Cylinder Head Temperature (CHT) sensor.
- Tighten to 11 Nm (97 lb-in).
8. Connect the Cylinder Head Temperature (CHT) sensor electrical connector.
9. NOTICE: Lubricate the O-ring seal with clean engine coolant prior to installing.
Using a new O-ring seal, install the coolant outlet pipe.
- Tighten to 10 Nm (89 lb-in).
LH cylinder head
10. Tighten the new LH cylinder head bolts in 4 stages in the sequence shown.
- Stage 1: Tighten to 25 Nm (18 lb-ft).
- Stage 2: Tighten to 40 Nm (30 lb-ft).
- Stage 3: Tighten an additional 90 degrees.
- Stage 4: Tighten an additional 90 degrees.
11. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraper to clean the sealing surfaces.
Clean the exhaust manifold mating surface of the cylinder head with metal surface prep. Follow the directions on the packaging.
12. Install 8 new LH exhaust manifold studs.
- Tighten to 25 Nm (18 lb-ft).
13. NOTE: The tightening specification differs between early build (coarse thread) and late build (fine thread) exhaust manifold nuts.
Install new gaskets, the LH exhaust manifold and 8 new nuts.
- Tighten early build (coarse thread) nuts in the sequence shown in 2 stages.
- Stage 1: Tighten to 28 Nm (21 lb-ft).
- Stage 2: Tighten to 37 Nm (27 lb-ft).
- Tighten late build (fine thread) nuts in the sequence shown in 2 stages.
- Stage 1: Tighten to 24 Nm (18 lb-ft).
- Stage 2: Tighten to 32 Nm (24 lb-ft).
14. Attach the wiring harness retainer to the LH cylinder head.
15. Using a new gasket, install the coolant outlet and 2 bolts.
- Tighten to 10 Nm (89 lb-in).
16. NOTE: Lubricate the camshaft roller follower and hydraulic lash adjuster assemblies with clean engine oil prior to installation.
Install the 16 camshaft roller follower and hydraulic lash adjuster assemblies.
17. NOTE: Lubricate the camshafts with clean engine oil prior to installation.
Install the LH intake and exhaust camshafts in the neutral position. Align the D-slots as shown in the illustration.
18. Install the 8 camshaft bearing caps and the 16 bolts. Do not tighten the bolts at this time.
19. Install the LH front camshaft bearing mega cap and the 4 bolts. Do not tighten the bolts at this time
20. Tighten the bolts in the sequence shown in 2 stages.
- Stage 1: Tighten to 6 Nm (53 lb-in).
- Stage 2: Tighten an additional 45 degrees.
21. NOTE: Intake camshaft shown, exhaust camshaft similar.
Install the Variable Camshaft Timing (VCT) system oil filter in the intake and exhaust camshafts.
22. Install the secondary timing chain onto the LH VCT assemblies. Align the colored links on the secondary timing chain with the timing marks on the VCT assemblies as shown in the illustration.
1. The timing mark on the intake VCT assembly should align between the 2 consecutive colored links.
2. The timing mark on the exhaust VCT assembly should align with the single colored link.
23. Install the LH VCT assemblies and the secondary timing chain onto the LH camshafts to a position 2 mm (0.078 in) from fully seated. The timing mark on the exhaust VCT assembly should be in the 11 o'clock position.
24. NOTE: It may be necessary to rotate the exhaust camshaft slightly (using a wrench on the flats of the camshaft) to seat the VCT assemblies onto the camshafts.
Rotate the secondary timing chain tensioner 90 degrees so the ramped area is facing forward and fully seat the VCT assemblies onto the camshafts.
- If the secondary timing chain is not centered over the tensioner, reposition the VCT assemblies until they are fully seated on the camshafts.
25. NOTE: Use a wrench on the flats of the camshaft to hold the camshafts while tightening the VCT assembly bolts.
Install the 3 LH intake VCT assembly bolts and the 3 LH exhaust VCT assembly bolts.
- Tighten to 15 Nm (133 lb-in) plus an additional 90 degrees.
26. Install the LH primary timing chain.
- Align the colored link on the timing chain with the timing mark on the LH VCT assembly.
27. Align the remaining colored link on the timing chain with the timing mark on the crankshaft sprocket.
28. NOTE: It may be necessary to rotate the crankshaft slightly to provide enough slack in the chain to install the LH timing chain guide. Return the crankshaft keyway to the 9 o'clock position after installing the LH timing chain guide.
Install the LH timing chain guide and bolt.
- Tighten to 10 Nm (89 lb-in).
29. NOTE: It may be necessary to rotate the crankshaft slightly to provide enough slack in the chain to install the LH timing chain tensioner arm. Return the crankshaft keyway to the 9 o'clock position after installing the LH timing chain tensioner arm.
Install the LH timing chain tensioner arm.
NOTE: Complete the following 3 steps on both the LH and RH primary timing chain tensioners.
30. NOTICE: Do not compress the ratchet assembly or damage to the tensioner will occur.
Compress the primary timing chain tensioner plunger, using an edge of a vise.
31. Using a small screwdriver or pick, push back and hold the ratchet mechanism, then push the ratchet arm back into the tensioner housing.
32. Install a suitable pin into the hole of the tensioner housing to hold the ratchet assembly and plunger in place during installation.
33. Install the LH primary timing chain tensioner and 2 bolts.
- Tighten to 10 Nm (89 lb-in).
- Remove the holding pin from the tensioner.
34. Using the crankshaft holding tool, rotate the crankshaft clockwise until the crankshaft keyway is at the 12 o'clock position.
35. With the crankshaft keyway at the 12 o'clock position, verify the timing mark alignment is correct.
RH cylinder head
36. NOTE: Lubricate the camshaft roller follower and hydraulic lash adjuster assemblies with clean engine oil prior to installation.
Install the 16 camshaft roller follower and hydraulic lash adjuster assemblies.
37. NOTE: Lubricate the camshafts with clean engine oil prior to installation.
Install the RH intake and exhaust camshafts in the neutral position. Align the D-slots as shown in the illustration.
38. Install the 8 camshaft bearing caps and the 16 bolts. Do not tighten the bolts at this time.
39. Install the RH front camshaft bearing mega cap and the 4 bolts. Do not tighten at this time
40. Tighten the bolts in the sequence shown in 2 stages.
- Stage 1: Tighten to 6 Nm (53 lb-in).
- Stage 2: Tighten an additional 45 degrees.