Installation Procedure
- NOTE:
- When reusing valve lifters (1), install the lifters to their original locations.
- Only replace the valve lifters (1) and valve lifter guides (2) as required.
- If camshaft replacement is required, the valve lifters (1) must also be replaced
Lubricate the valve lifters (1), valve lifter guides (2) and the engine block valve lifter bores with clean engine oil. Adhesives, Fluids, Lubricants, and Sealers
- Install the raised surface of the valve lifter (1) into the notched area of the valve lifter guide (2).
- NOTE:
The notched area of the valve lifter guides (2) align with the locating tab on the engine block.
Install the valve lifter guide (2) and the valve lifters (1) as an assembly.
- Valve Lifter Guide Bolt (3) - Install and tighten - Fastener Specifications
Cylinder Head Gasket (2) - Install NEW
- Cylinder Head (1) - Install
- CAUTION:
This vehicle is equipped with torque-to-yield or single use fasteners. Install a NEW torque-to-yield or single use fastener when installing this component. Failure to replace the torque-to-yield or single use fastener could cause damage to the vehicle or component.
Cylinder Head Bolt (1) - Install NEW and hand tighten [10x]
- Cylinder Head Bolt (1) - Tighten in sequence [10x] - Fastener Specifications
- NOTE:
Some components not shown for graphic clarity.
Generator Bolt (1) - Install and tighten - Fastener Specifications
Oil Level Indicator Tube Bolt (1) @ Cylinder Head - Right Side - Install and tighten - Fastener Specifications
Engine Wiring Harness (2) @ Cylinder Head - Connect
- Engine Wiring Harness Ground Bolt (1) - Install and tighten - Ground Repair
Lubricate the flange of the 8 valve rocker arm bolts with clean engine oil. Adhesives, Fluids, Lubricants, and Sealers
- Lubricate the 8 valve rocker arms and push rods with clean engine oil. Adhesives, Fluids, Lubricants, and Sealers
- Valve lash is net build. No valve adjustment is required.
- Ensure the push rods seat properly to the valve lifter sockets.
- Valve Push Rod (1) - Install [8x]
- NOTE:
The rocker arm bolts are not serviced separately.
Valve Rocker Arm (2) - Install [8x]
- Valve Rocker Arm Pivot Support Bolt (1) - Hand tighten [8x]
- Valve Rocker Arm Pivot Support Bolt (1) - Tighten [8x] - Fastener Specifications
Valve Rocker Arm Cover Gasket (2) @ Valve Rocker Arm Cover (1) - Install NEW
- NOTE:
Some components not shown for graphic clarity.
Valve Rocker Arm Cover - Right Side (2) - Install
- Valve Rocker Arm Cover Bolt (1) - Hand tighten [10x]
- Valve Rocker Arm Cover Bolt (1) - Tighten in sequence [10x] - Fastener Specifications
- Engine Wiring Harness Connector @ Ignition Coil - Connect [4x]
Heater Inlet and Outlet Hose Bracket (2) - Reposition
- Heater Hose Clip Bracket Bolt (1) - Install and tighten - Fastener Specifications
Valve Rocker Arm Cover Insulator (3) - Install
- Install the 3 upper intake manifold sight shield grommets (2) to the 3 valve rocker arm cover insulator retainers (1).
- NOTE:
Do NOT reuse the fuel feed intermediate pipe (1). If the 2 fuel feed intermediate pipe nuts (3) are loosened or the fuel feed intermediate pipes are removed, the fuel feed intermediate pipes MUST be replaced.
Fuel Feed Intermediate Pipe (1) - Install NEW
- Slide the 2 fuel feed intermediate pipe nuts (3) back along fuel feed intermediate pipe (1) to reveal the 2 formed ends (2) of the fuel feed intermediate pipe (1).
- Carefully install the 2 formed ends (2) of the fuel feed intermediate pipe (1) into the sockets of the left and right fuel injection fuel rail. Take care not to hit the 2 formed ends (2) of the fuel feed intermediate pipe (1) on the threaded sockets on the fuel injection fuel rails.
- Hold the fuel feed intermediate pipe (1) firmly in place and hand tighten the 2 fuel feed intermediate pipe nuts (3).
- Fuel Feed Pipe Bolt (4) - Tighten - Fastener Specifications
- Fuel Feed Intermediate Pipe Nut (3) - Tighten [2x] - Fastener Specifications
- NOTE:
Do NOT reuse the fuel feed intermediate pipe (1). If the 2 fuel feed intermediate pipe nuts (2) are loosened or the fuel feed intermediate pipes are removed, the fuel feed intermediate pipes MUST be replaced.
Fuel Feed Intermediate Pipe (1) - Install NEW
- Slide the 2 fuel feed intermediate pipe nuts (2) back along fuel feed intermediate pipe (1) to reveal the 2 formed ends (3) of the fuel feed intermediate pipe (1).
- Carefully install the 2 formed ends (3) of the fuel feed intermediate pipe (1) into the sockets of the fuel pump (4) and the fuel feed intermediate pipe (5). Take care not to hit the 2 formed ends (3) of the fuel feed intermediate pipe (1) on the threaded sockets of the fuel pump (4) and fuel feed intermediate pipe (5).
- Hold the fuel feed intermediate pipe (1) firmly in place and hand tighten the 2 fuel feed intermediate pipe nuts (2).
- Fuel Feed Intermediate Pipe Nut (2) - Tighten [2x] - Fastener Specifications
- Connect the electrical wiring harness connectors from the fuel rails.
- WARNING:
The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.
Fuel Pump Insulator (1) - Install
- Remove the covers from the cylinder head passages.
Intake Manifold Gasket (1) - Install NEW [8x]
If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:
- Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
- Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
- Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
- Ensure there are no gaps in the thread locking adhesive once applied to the component.
- Position the intake manifold and Intake manifold cover (1) to install harness retainers.
Engine Wiring Harness Retainer (1) @ Intake Manifold Cover (2) - Install [4x]
- Move the intake manifold and intake manifold cover (2) into place.
- NOTE:
Some components not shown for graphic clarity.
Intake Manifold Bolt (1) - Hand tighten [10x]
- Intake Manifold Bolt (1) - Tighten in sequence [10x] - Fastener Specifications
Positive Crankcase Ventilation Tube Connector (2) @ Intake Manifold - Install - Plastic Collar Quick Connect Fitting Service
Engine Wiring Harness Retainer (1) @ Intake Manifold Cover (2) - Install [3x]
Engine Wiring Harness Retainer (1) @ Intake Manifold Cover (2) - Install [4x]
Engine Wiring Harness Connector (4) @ Evaporative Emission Canister Purge Solenoid Valve - Connect
- Engine Wiring Harness Connector (3) @ Manifold Absolute Pressure Sensor - Connect
- Engine Wiring Harness Retainer (2) @ Intake Manifold Cover - Install [2x]
- Engine Wiring Harness Connector (1) @ Throttle Body - Connect
Evaporative Emission Canister Purge Tube (2) @ Evaporative Emission Canister Purge Solenoid Valve - Install
- Evaporative Emission Canister Purge Tube Connector (1) @ Evaporative Emission Canister Purge Solenoid Valve - Engage - Plastic Collar Quick Connect Fitting Service
Air Cleaner Outlet Duct (3) - Install
- Air Cleaner Outlet Duct Clamp (2) - Tighten [2x] - Fastener Specifications
Air Cleaner Outlet Duct Bracket Bolt (1) - Install and tighten - Fastener Specifications
- Install engine wiring harness to air cleaner outlet duct bracket.
Positive Crankcase Ventilation Fresh Air Tube (1) - Install
- Positive Crankcase Ventilation Tube Connector (3) @ Positive Crankcase Ventilation Fitting - Connect - Plastic Collar Quick Connect Fitting Service
- Positive Crankcase Ventilation Tube Connector (2) @ Air Cleaner Outlet Duct - Connect - Plastic Collar Quick Connect Fitting Service
- Raise the vehicle.
Exhaust System Seal - Right Side (1) - Install NEW
Exhaust Manifold Gasket - Right Side (2) - Install NEW
- Install the right side exhaust manifold (1) through the wheel opening.
If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:
- Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
- Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
- Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
- Ensure there are no gaps in the thread locking adhesive once applied to the component.
- Exhaust Manifold Bolt - Right Side (1) - Install and hand tighten [5x]
- Exhaust Manifold Bolt - Right Side (1) - Tighten in sequence [5x] - Fastener Specifications
Exhaust Front Pipe Nut - Right Side (1) - Install and hand tighten [3x]
- Exhaust Front Pipe Nut - Right Side (1) - Tighten [3x] - Fastener Specifications
- NOTE:
A special anti-seize compound is used in the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before reinstallation. Adhesives, Fluids, Lubricants, and Sealers
Using a suitable tool, install and tighten the heated oxygen sensor (1). Fastener Specifications
- Connect the heated oxygen sensor electrical connector.
Retainer Clip (1) @ Cylinder Head - Right Side (2) - Install
Exhaust Front Pipe Heat Shield (2) - Install
- Exhaust Heat Shield Bolt (1) - Install and tighten - Fastener Specifications
Install the right exhaust manifold heat shield (1) through the wheel opening.
Exhaust Manifold Heat Shield Bolt - Right Side (1) - Install and hand tighten [3x]
- Exhaust Manifold Heat Shield Bolt - Right Side (1) - Tighten [3x] - Fastener Specifications
Inspect the inside of the spark plug rubber boots for a thin, even coat of grease. If there is no grease present or additional grease is necessary, apply a thin coating of dielectric grease evenly to the inside of the spark plug rubber boots up to a depth of 15 mm (0.6 in) from the end of the boot. Adhesives, Fluids, Lubricants, and Sealers
- Push the 4 boots of the spark plug wires (1) onto the 4 gas engine ignition spark plugs (2) until 2 audible clicks are heard.
- Install the wiring harness.
- Front Wheelhouse Liner - Right Side (3) - Install Front Wheelhouse Liner Replacement
- Engine Oil and Oil Filter - Install NEW - Engine Oil and Oil Filter Replacement
Plenum Front Panel Outer Reinforcement (1) - Install - Plenum Front Panel Outer Reinforcement Removal and Installation
- Fill the cooling system to the proper level. Cooling System Draining and Filling (GE 47716 L84, L87) , or Cooling System Draining and Filling (Static L84, L87)
- Start the engine and check for leaks.
Refer to Fastener Caution .
The aid of an assistant may be helpful in holding the engine harness up out of the way so the upper intake manifold cover does not get caught against the engine harness.