Cylinder Head RH: Installation

All Vehicles 

1. Install the new cylinder head gasket.

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2. NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.
   1. Install the cylinder head and the new bolts.

      Torque: Stage 1: Bolts 1-10 in sequence: 18 lb.ft (25 Nm) Stage 2: Bolts 1-10 in sequence: 55 lb.ft (75 Nm) Stage 3: Bolt 1: Loosen: 180 deg. Stage 4: Bolt 1: 37 lb.ft (50 Nm) Stage 5: Bolt 1: 240 deg.

   2. Perform stages 3, 4 and 5 on bolts 2 through 10 (complete all three stages to each bolt before moving on to the next bolt in sequence).
   Fig 1: Cylinder Head (LH) Bolts Tightening Sequence

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3. Install the insulators.

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4. NOTE: In stage 3, if the torque required to tighten any flare nut on the new high-pressure fuel tube reaches or exceeds 55 lb.ft (50 Nm), then that high pressure fuel tube must be discarded and replaced with another new high-pressure fuel tube.

   Torque: Stage 1: Tighten the high-pressure fuel tube flare nuts to : 71 lb.in (8 Nm) Stage 2: Tighten the high-pressure fuel tube flare nuts to : 89 lb.in (10 Nm) Stage 3: Tighten the high-pressure fuel tube flare nuts an additional : 25 deg.

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5. 1. Connect the fuel rail electrical connector.
   2. Connect the CHT sensor electrical connector.

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6. Connect the heater hose.

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7. NOTE: Do not position the legs of the Engine Support Bar on the fenders. Instead, the legs should be positioned on the body structure. Failure to follow these instructions may result in body damage.

   Install the special tools and raise the engine 25 mm (1 inch). Install Special Service Tool: 303-639 Support Bracket, Engine., 303-F070 Support Bar, Engine.

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8. Remove the bolts, the stud bolts and the RH engine mount bracket.

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9. Install new studs and new gasket.

   Torque: 18 lb.ft (25 Nm)

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10. Install the exhaust manifold.
    • Install the new nuts.

      Torque: Stage 1: 18 lb.ft (24 Nm) Stage 2: 24 lb.ft (32 Nm)

    Fig 2: Exhaust Manifold RH Bolts Tightening Sequence

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11. Install the RH engine mount bracket, bolts and stud bolts.

    Torque: 46 lb.ft (62.5 Nm)

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12. • Install the ground strap and nut onto the RH engine mount bracket stud bolt.

      Torque: 35 lb.ft (48 Nm)

    • Attach the wiring harness retainers to the oil pan.
    • Connect the A/C compressor electrical connector.

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13. • Using the special tools, lower the engine onto the engine mounts.
    • Remove Special Service Tool: 303-F070 Support Bar, Engine., 303-639 Support Bracket, Engine.

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14. Install the RH engine mount nut.

    Torque: 46 lb.ft (63 Nm)

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15. Install the LH engine mount nut.

    Torque: 46 lb.ft (63 Nm)

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    10-Speed Automatic Transmission - 10R80 

16. Install the transmission cooling tube bracket and nut.

    Torque: 35 lb.ft (48 Nm)

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17. Install the transmission cooling tube bracket and nut.

    Torque: 124 lb.in (14 Nm)

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18. Disconnect the HO2S electrical connector.

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    6-Speed Manual Transmission - 3160/6-Speed Manual Transmission - MT82 

19. 1. Connect the HO2S electrical connector.
    2. Attach the wiring harness retainer.

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    All Vehicles 

20. NOTE: The drain plug should be removed and installed by hand, do not use tools.
    1. Turn the oil drain plug by hand counterclockwise 120 degrees. Use the General Equipment: Oil Drain Equipment
    2. Pull the oil drain plug out of the oil pan.
    3. After the oil has drained, push the oil drain plug into the oil pan.
    4. NOTE: Overtightening will damage the oil drain plug and possibly the oil pan.

       Turn the oil drain plug by hand clockwise 120 degrees.

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21. NOTE: GT vehicle shown, Mach 1 similar.

    Remove and discard the engine oil filter.

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22. NOTE: GT vehicle shown, Mach 1 similar.
    NOTE: Do not lubricate the O-ring seal.

    Install a new oil filter.

    Torque: Stage 1: 44 lb.in (5 Nm) Stage 2: 180 deg.

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23. Install the following items:
    1. Starter. Refer to: Starter Motor
    2. Battery tray. Refer to: Battery Tray
    3. Evaporator outlet line. Refer to: Evaporator Outlet Line - 5.0L 32V Ti-VCT
    4. A/C compressor inlet line. Refer to: Air Conditioning (A/C) Compressor Inlet Line - 5.0L 32V Ti-VCT
    5. RH catalytic converter. Refer to: Catalytic Converter RH
    6. RH camshafts. Refer to: Camshaft RH 

24. Install the radiator top shield and the retainers.

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25. Fill the engine with clean engine oil. Refer to: Specifications 
26. Connect the battery ground and positive cables. Refer to: Battery Disconnect and Connect
27. Pressurize the fuel system. Refer to: Fuel System Pressure Release
28. Fill and bleed the engine cooling system. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding
29. Recharge the A/C system.
30. Use the Powertrain Control Module (PCM) Misfire Monitor Profile Correction routine in the diagnostic scan tool.
31. Road test the vehicle.