Cylinder Head: Assembly

WARNING: This page is about a different variant/trim than selected.

All cylinder heads

Install the valve.

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NOTE: Lubricate the valve stem seal with clean engine oil prior to installation.

Using the special tool, install the valve stem seal. Use Special Service Tool: 303-470 (T94P-6510-CH) Installer, Valve Stem Oil Seal.

Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)

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Using the special tools, install the valve spring, valve spring retainer and the valve collet. Use Special Service Tool: 303-300 (T87C-6565-A) Set, Valve Spring Compressor, 303-350 (T89P-6565-A) Compressor, Valve Spring, 303-1249 Valve Spring Compressor.

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Repeat the previous 3 steps for each valve.
Install the spark plugs. Refer to: Spark Plugs .
Note the fuel injector seal backup ring orientation for installation.

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NOTE: Use care when removing the lower Teflon® seals, not to scratch, nick or gouge the fuel injectors.

NOTE: Do not attempt to cut the lower Teflon® seal without first pulling it away from the fuel injector or damage to the injector may occur.
1. Pull the lower Teflon® seal away from the injector.
2. Carefully cut and discard the lower fuel injector Teflon® seals.
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NOTE: Do not lubricate the new lower Teflon® fuel injector seals.
1. Use Special Service Tool: 310-207 Installer, Fuel Injector Seal Assembly.
2. NOTE: Once the Teflon® seal is installed on the Teflon® Seal Guide, it should immediately be installed onto the fuel injector to avoid excessive expansion of the Teflon® seal.
  
  NOTE: Make sure that new lower fuel injector Teflon® seals are installed.
3. Using the Pusher Tool, slide the Teflon® seals off of the Teflon® Seal Guide and into the groove on the fuel injectors. Use Special Service Tool: 310-207 Installer, Fuel Injector Seal Assembly.
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NOTE: Install the fuel injectors into the cylinder head within 15 minutes of sizing the seals due to Teflon® seal expansion.

NOTE: Make sure the Teflon® seal is fully seated in the groove on the fuel injector before sizing the Teflon® seal.
1. Some Teflon® seal massaging with your fingers before the Teflon® Seal Sizer tool is installed will aid in installing the Teflon® Seal Sizer tool.
2. Position the Teflon® Seal Sizer tool with the larger opening towards the Teflon® seal. Push while turning the Teflon® Seal Sizer tool 180 degrees. Use Special Service Tool: 303-1567 Sizer, Teflon Seal.
3. Once the Teflon® Seal Sizer tool is installed, check and make sure the Teflon® seal is in the sizing portion of the Teflon® Seal Sizer tool. After one minute, turn the Teflon® Seal Sizer tool back 180 degrees and remove.
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1. NOTE: The large diameter step of the backup ring must go up towards the new O-ring seal. Improperly installed backup rings may cause the fuel system to leak.
2. NOTE: Use fuel injector O-ring seals that are made of special fuel-resistant material. The use of ordinary O-ring seals may cause the fuel system to leak. Do not reuse the O-ring seals.
  
  NOTE: Do not lubricate the new lower Teflon® fuel injector seals.
  
  Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)
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NOTE: RH shown, LH similar.
- NOTE: The anti-rotation finger of the fuel injector must slip into the groove of the fuel rail cup.
  
  Install the fuel injectors into the fuel rail.
- Connect the fuel injector electrical connectors.
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NOTE: Do not lubricate the new lower Teflon® fuel injector seals.

NOTE: Make sure that new fuel rail bolts are installed.

NOTE: Push down on the fuel rail above the injectors.

Install the fuel injectors and fuel rail assembly into the cylinder head and install the new bolts.

Torque: Stage 1: 71 lb.in (8 Nm) Stage 2: Wait 5s Stage 3: 124 lb.in (14 Nm) Stage 4: 30 deg.

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RH cylinder head
Install the timing chain tensioner arm and timing chain guide pins.
Torque: 89 lb.in (10 Nm)

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Install the new the studs and the exhaust manifold gasket.
Torque: 106 lb.in (12 Nm)

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Install the exhaust manifold and the new nuts.
Torque: Stage 1: 168 lb.in (19 Nm) Stage 2: 18 lb.ft (25 Nm)

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1. Install the stud bolt.
  Torque: Stage 1: 89 lb.in (10 Nm) Stage 2: 20 deg.
2. Install the new CHT sensor.
  Torque: 97 lb.in (11 Nm)
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Install the turbocharger coolant supply tube and fitting.
Torque: 159 lb.in (18 Nm)

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LH cylinder head
Install the timing chain guide pin.
Torque: 89 lb.in (10 Nm)

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Install the lift eye bracket and the bolts.
Torque: 18 lb.ft (24 Nm)

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Install the new the studs and the exhaust manifold gasket.
Torque: 106 lb.in (12 Nm)

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Install the exhaust manifold and the new nuts.
Torque: Stage 1: 168 lb.in (19 Nm) Stage 2: 18 lb.ft (25 Nm)

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Install the turbocharger coolant supply tube and fitting.
Torque: 159 lb.in (18 Nm)

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