Cylinder Head: Installation: Installation

Fig 1: Tensioner Mounting Stud

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If removed, install the tensioner mounting stud to the cylinder head and tighten to 11 N.m (97 in. lbs.).

Fig 2: Thermostat Housing Assembly, Engine Coolant Temperature Sensor & Fasteners
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If removed, install the thermostat housing and gasket with bolts (2) tightened to 10 N.m (89 in. lbs.).

Fig 3: Checking Cylinder Head Bolts For Stretching (Necking)
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CAUTION:
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.
Check cylinder head bolts for necking by holding a scale or straight edge against the threads. If all the threads do not contact the scale (2) the bolt must be replaced.

Fig 4: Cylinder Head Gasket & Locating Dowels
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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.
Clean and prepare the gasket sealing surfaces of the cylinder head and block.
Refer to STANDARD PROCEDURE .
Install two cylinder head locating dowels (2).
Position the new cylinder head gasket (1) on the locating dowels (2).

Fig 5: Cylinder Head Bolt Tightening Sequence
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Position the cylinder head onto the cylinder block. Make sure the cylinder head seats fully over the locating dowels.
Install the ten head bolts finger tight.
Tighten the cylinder head bolts in the sequence shown in illustration:
- Step 1: All to 20 N.m (15 ft. lbs.).
- Step 2: All to 30 N.m (22 ft. lbs.).
- Step 3: All + 90° Turn
  Do not use a torque wrench for this step.
- Step 4: All an additional + 90° Turn
  Do not use a torque wrench for this step.
Fig 6: Heater Core Inlet Hose, Engine Coolant Temperature (ECT) Sensor Electrical Connector & Cylinder Head Coolant Outlet Flange
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Connect the heater core inlet hose (1).
Connect and lock the Engine Coolant Temperature (ECT) sensor wire harness connector (2).

Fig 7: Oil Filter Housing Coolant Return Hose O-Ring
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Apply engine oil to the oil filter housing coolant return hose O-ring (1).

Fig 8: Thermostat Housing, Pressurized Coolant Bottle Return Hose, Clamp & Bolt
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Install the oil filter housing coolant return hose to the thermostat housing (1). Tighten the bolt (4) to 9 N.m (80 in. lbs.).
CAUTION:
The vacuum hose and the pressurized coolant bottle return hose have the same quick-connect fitting end. Verify that the hoses are correctly installed. Failure to properly install the hoses can result in engine damage.
Connect the afterrun coolant pump hose (2).
Connect the lower radiator hose and tighten the clamp (3).

Fig 9: Side Timing Belt Cover & Bolt
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Install the side timing belt cover (1) with bolt (2) tightened to 25 N.m (18 ft. lbs.).

Fig 10: Intake Manifold Flange Bolts
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Install the intake manifold.
Refer to MANIFOLD, INTAKE, INSTALLATION .

Fig 11: Exhaust Manifold Nuts
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Install the exhaust manifold.
Refer to MANIFOLD, EXHAUST, INSTALLATION .

Fig 12: Camshaft Bearing Housing Bolt Tightening Sequence
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Install the camshaft bearing housing.
Refer to HOUSING, CAMSHAFT BEARING, INSTALLATION .
If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level.
Refer to OIL, STANDARD PROCEDURE .
Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level.
Refer to STANDARD PROCEDURE .

NOTE:
The Cam/Crank Variation Relearn procedure must be performed using the scan tool anytime there has been a repair/replacement made to a powertrain system. For example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components. Refer to STANDARD PROCEDURE .