Cylinder Head - RH: Installation

NOTE: 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.

NOTE: If the cylinder head is replaced, a new secondary timing chain tensioner will need to be installed.

NOTE: The valve tappets must be installed in their original positions. Coat the valve tappets with clean engine oil prior to installation.

1.

Install a new gasket, the RH cylinder head and 8 new bolts. Tighten the bolts in the sequence shown below in 5 stages:
- Stage 1: Tighten to 20 Nm (177 lb-in).
- Stage 2: Tighten to 35 Nm (26 lb-ft).
- Stage 3: Tighten 90 degrees.
- Stage 4: Tighten 90 degrees.
- Stage 5: Tighten 45 degrees.

Fig 1: RH Cylinder Head Bolts Tightening Sequence

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2.

Install the bolt.
- Tighten to 10 Nm (89 lb-in).

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NOTE: Coat the valve tappets with clean engine oil prior to installation.

NOTE: The valve tappets must be installed in their original positions.

3.
Install the valve tappets.

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4.

Connect the CHT sensor jumper harness.

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NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

5.
Using new intake manifold and thermostat housing gaskets, install the lower intake manifold and the 10 bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).

Fig 2: Lower Intake Manifold Bolts Tightening Sequence

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6.

Install the 2 thermostat housing-to-lower intake manifold bolts.
- Tighten to 10 Nm (89 lb-in).

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NOTE: Align the bracket with the index mark made during removal.

7.
Install the upper intake manifold bracket and the bolt.
- Tighten to 10 Nm (89 lb-in).

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8.

Install the engine lifting eye and the 2 bolts.
- Tighten to 24 Nm (18 lb-ft).

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9.

Install the RH primary timing chain guide and the bolt.
- Tighten to 10 Nm (89 lb-in).

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10.

If equipped, install the block heater wiring harness onto the engine.
- Tighten the cylinder block drain plug to 10 Nm (89 lb-in) plus an additional 720 degrees.
- Tighten the block heater to 40 Nm (30 lb-ft).

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11.

Install 6 new RH exhaust manifold studs.
- Tighten to 12 Nm (106 lb-in).

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NOTE: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.

12.
Using a new gasket, install the RH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown:
- Stage 1: Tighten to 20 Nm (177 lb-in).
- Stage 2: Tighten to 25 Nm (18 lb-ft).

Fig 3: RH Exhaust Manifold Nuts Tightening Sequence

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13.

Install the RH catalytic converter heat shield and the 4 bolts.
- Tighten to 10 Nm (89 lb-in).

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14.

Install the LH cylinder block drain plug.
- Tighten to 16 Nm (142 lb-in) plus an additional 180 degrees.

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15.

Install the ground cable and bolt to the RH cylinder head.
- Tighten to 10 Nm (89 lb-in).

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16.

Install the 2 CMP sensors and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).

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17.

Connect the 2 RH CMP sensor electrical connectors.

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18.

If equipped, connect the block heater electrical connector.
- Install the block heater wiring harness to the engine.

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19.

If equipped, install the block heater heat shield.

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20.

Install the RH camshafts. Refer to Camshaft .