Cylinder Head: Assembly

All cylinder heads 

• 1.
  
  Install the valve.

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NOTE: Lubricate the valve stem seal with clean engine oil prior to installation.
• 2.
  Using the valve stem oil seal installer, install the valve stem seal.

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• 3.
  
  Using the Valve Spring Compressor, install the valve spring, valve spring retainer and the valve collet.

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• 4.
  
  Repeat the previous 3 steps for each valve.

• 5.
  
  Install the spark plugs. Refer to: Engine Ignition System - 3.5L GTDI .

• 6.
  
  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.
• 7.
  

  • 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.
• 8.
  

  • 1.
    
    Use Special Service Tool: 310-207.
  NOTE: Make sure that new lower fuel injector Teflon ® seals are installed.
  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.
  • 2.
    

  • 3.
    
    Using the Pusher Tool, slide the Teflon ® seals off of the Teflon ® Seal Guide and into the groove on the fuel injectors.

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NOTE: Make sure the Teflon ® seal is fully seated in the groove on the fuel injector before sizing the Teflon ® seal.
NOTE: Install the fuel injectors into the cylinder head within 15 minutes of sizing the seals due to Teflon ® seal expansion.
• 9.
  

  • 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.

  • 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.
  
  
  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.
  • 1.
    
  NOTE: Do not lubricate the new lower Teflon ® fuel injector seals.
  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.
  • 2.
    

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NOTE: RH shown, LH similar.
• 11.
  
  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: Push down on the fuel rail above the injectors.
NOTE: Make sure that new fuel rail bolts are installed.
NOTE: Do not lubricate the new lower Teflon ® fuel injector seals.
• 12.
  Install the fuel injectors and fuel rail assembly into the cylinder head and install the new bolts.
  • Stage 1: Tighten to 71 lb.in (8 Nm)
  • Stage 2: Wait 5 sec
  • Stage 3: Tighten to 124 lb.in (14 Nm)
  • Stage 4: Tighten an additional 30 °

RH cylinder head 

• 13.
  
  Install the timing chain tensioner arm and timing chain guide pins.
  • Tighten to 89 lb.in (10 Nm)

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• 14.
  
  Install the new the studs and the exhaust manifold gasket.
  • Tighten to 106 lb.in (12 Nm)

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• 15.
  
  Install the exhaust manifold and the new nuts.
  • Stage 1: Tighten to 168 lb.in (19 Nm)
  • Stage 2: Tighten to 18 lb.ft (25 Nm)

• 16.
  
  

  • 1.
    
    Install the stud bolt.
    • Stage 1: Tighten to 89 lb.in (10 Nm)
    • Stage 2: Tighten an additional 20 °

  • 2.
    
    Install the new CHT sensor.
    • Tighten to 97 lb.in (11 Nm)

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• 17.
  
  Install the turbocharger coolant supply tube and fitting.
  • Tighten to 159 lb.in (18 Nm)

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LH cylinder head 

• 18.
  
  Install the timing chain guide pin.
  • Tighten to 89 lb.in (10 Nm)

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• 19.
  
  Install the lift eye bracket and the bolts.
  • Tighten to 18 lb.ft (24 Nm)

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• 20.
  
  Install the new the studs and the exhaust manifold gasket.
  • Tighten to 106 lb.in (12 Nm)

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• 21.
  
  Install the exhaust manifold and the new nuts.
  • Stage 1: Tighten to 168 lb.in (19 Nm)
  • Stage 2: Tighten to 18 lb.ft (25 Nm)

• 22.
  
  Install the turbocharger coolant supply tube and fitting.
  • Tighten to 159 lb.in (18 Nm)

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