Cylinder Head: Assembly

All cylinder heads 

1. Install the valve.

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2. 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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3. 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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4. Repeat the previous 3 steps for each valve.
5. Install the spark plugs. Refer to: Spark Plugs .
6. Note the fuel injector seal backup ring orientation for installation.

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7. 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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8. 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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9. 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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10. 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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11. NOTE: RH shown in illustration, 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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12. 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°

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    RH cylinder head 

13. Install the timing chain tensioner arm and timing chain guide pins.

    Torque: 89 lb.in (10 Nm)

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14. NOTE: Cylinder head equipped with cast iron exhaust manifold.

    Install the new the studs and the exhaust manifold gasket.

    Torque: 115 lb.in (13 Nm)

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15. NOTE: Cylinder head equipped with cast iron exhaust manifold.

    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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16. NOTE: Cylinder head equipped with stainless steel exhaust manifold.

    Install the new the studs and the exhaust manifold gasket.

    Torque: 115 lb.in (13 Nm)

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17. NOTE: Cylinder head equipped with stainless steel exhaust manifold.

    Install the exhaust manifold and the new nuts.

    Torque:

    Stage 1: 168 lb.in (19 Nm)

    Stage 2: 16 lb.ft (22 Nm)

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18. 1. Install the stud bolt.

       Torque:

       Stage 1: 89 lb.in (10 Nm)

       Stage 2: 20°

    2. Install the new CHT sensor.

       Torque: 97 lb.in (11 Nm)

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19. Install the turbocharger coolant supply tube and fitting.

    Torque: 159 lb.in (18 Nm)

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    LH cylinder head 

20. Install the timing chain guide pin.

    Torque: 89 lb.in (10 Nm)

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21. Install the lift eye bracket and the bolts.

    Torque: 18 lb.ft (24 Nm)

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22. NOTE: Cylinder head equipped with cast iron exhaust manifold.

    Install the new the studs and the exhaust manifold gasket.

    Torque: 115 lb.in (13 Nm)

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23. NOTE: Cylinder head equipped with cast iron exhaust manifold.

    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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24. NOTE: Cylinder head equipped with stainless steel exhaust manifold.

    Install the new the studs and the exhaust manifold gasket.

    Torque: 115 lb.in (13 Nm)

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25. NOTE: Cylinder head equipped with stainless steel exhaust manifold.

    Install the exhaust manifold and the new nuts.

    Torque:

    Stage 1: 168 lb.in (19 Nm)

    Stage 2: 16 lb.ft (22 Nm)

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26. Install the turbocharger coolant supply tube and fitting.

    Torque: 159 lb.in (18 Nm)

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