Tools Required

1. Lubricate the valve stems with engine oil.
2. Carefully install the valves in their original positions.
3. Install the valve springs in their original positions.
4. Install the valve spring caps.
5. Compress the valve springs with the valve spring compressor EN 47518 and the KM-635 .
6. Install the valve keys.
7. Remove the valve spring compressor KM-348 and the KM-635 .



8. Lubricate the valve tappet adjusters with engine oil.
9. Install the valve tappet adjusters.



10. Install the intake camshaft.
11. Install the intake camshaft bearing caps in their original positions.
12. Install the exhaust camshaft.
13. Install the exhaust camshaft bearing caps in their original positions.

Notice: Refer to Fastener Notice in the Preface section.

14. Install the camshaft bearing cap bolts gradually in the sequence shown for each camshaft cap.

Tighten
Tighten the camshaft bearing cap bolts to 8 N·m (71 lb in).




15. Install the spark plugs.

Tighten
Tighten the spark plugs to 25 N·m (18 lb ft).

16. Install the DIS coil and EGR valve adapter.

Tighten
Tighten the direct ignition system coil and the exhaust gas recirculation valve adapter retaining bolts to 25 N·m (18 lb ft).




17. Install the intake manifold studs.
18. Install the intake manifold gasket.
19. Install the intake manifold.
20. Install the intake manifold retaining bolt and nuts in the sequence shown.

Tighten
Tighten the intake manifold retaining bolt and nuts to 22 N·m (16 lb ft).

21. Install the intake manifold support bracket.

Tighten
Tighten the intake manifold support bracket bolts to 25 N·m (18 lb ft).

22. Install the fuel rail assembly. Refer to Fuel Injection Fuel Rail Assembly Replacement .



23. Install the thermostat housing assembly.

Tighten
Tighten the thermostat housing assembly mounting bolts to 15 N·m (11 lb ft).

24. Install the coolant bypass housing and mounting bolts.

Tighten
Tighten the coolant bypass housing bolts to 15 N·m (11 lb ft).

25. Install the exhaust manifold studs.
26. Install the exhaust manifold gasket.
27. Install the exhaust manifold.
28. Install the exhaust manifold retaining nuts in the sequence shown.

Tighten
Tighten the exhaust manifold retaining nuts to 22 N·m (16 lb ft).




29. Install the exhaust manifold heat shield.

Tighten
Tighten the exhaust manifold heat shield bolts to 8 N·m (71 lb in).

30. Install the cylinder head with the intake manifold and the exhaust manifold attached. Refer to Cylinder Head Replacement .