Cylinder Head: Installation

Install the new cylinder head gasket.

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Install new catalytic converter studs and a new gasket.
Torque: 150 lb.in (17 Nm)

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NOTE: When removing or installing the cylinder head, use care to prevent excessive movement of the turbocharger. Excessive movement may cause damage to the turbocharger oil return tube resulting in an engine oil leak.
1. Slide the cylinder head and studs into the exhaust manifold.
2. Align the cylinder head to the locating dowels in the cylinder block and install.
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NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.

Install the cylinder head and the new bolts and tighten in sequence shown in illustration in 5 stages.

Torque: Stage 1: 62 lb.in (7 Nm)

Stage 2: 133 lb.in (15 Nm)

Stage 3: 26 lb.ft (35 Nm)

Stage 4: 90°

Stage 5: 135°

Fig 1: Cylinder Head Tightening Sequence
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Lubricate with clean engine oil and install the valve tappets in their original positions.

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- Install the fuel rail insulator.
- Connect the wiring harness electrical connectors.
- Attach the wiring harness retainers.
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Attach the EGR valve to the cylinder head.
- Install a new EGR gasket.
1. Install the EGR valve retaining bolts.
  Torque: 18 lb.ft (25 Nm)
2. Install the ground cable retaining bolt.
  Torque: 106 lb.in (12 Nm)
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Attach the coolant connector to the cylinder head and tighten the bolts.
Torque: 97 lb.in (11 Nm)

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Install new catalytic converter manifold studs.
Torque: 150 lb.in (17 Nm)

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Install the new nuts and tighten in sequence shown in illustration.
Torque: Stage 1: Tighten: 41 lb.ft (55 Nm)

Stage 2: Retighten: 41 lb.ft (55 Nm)

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- Install the catalytic converter heat shield and the bolts.
  Torque: 89 lb.in (10 Nm)
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Connect the catalyst monitor sensor electrical connector and wire retainer.

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- Remove the drain plug and drain the engine oil.
  Use the General Equipment: Oil Drain Equipment
- NOTE: The oil drain plug with O-ring seal is to be reused unless damaged.
  
  Install drain plug.
  
  Torque: 21 lb.ft (28 Nm)
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Remove and discard the engine oil filter.
Use the General Equipment: Oil Drain Equipment

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NOTE: Lubricate the engine oil filter gasket with clean engine oil prior to installing the oil filter.

Install a new engine oil filter.

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

Stage 2: 225°

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Install the following items:
1. Install the camshafts. Refer to: Camshaft .
2. Install the cowl panel. Refer to: Cowl Panel .
3. Install the intake manifold. Refer to: Intake Manifold .
Connect the battery ground. Refer to: BATTERY DISCONNECT AND CONNECT .
Fill the engine with clean engine oil. Refer to: Specifications .

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Fill and bleed the cooling system. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding .