Installation

INSTALLATION

Fig. 32 Head Gasket Installation:

1. Clean all surfaces of cylinder block and cylinder heads.
2. Install new gaskets on cylinder block Fig. 32.

WARNING: Intake manifold gasket is made of very thin metal and may cause personal injury. Handle with care.

Fig. 33 Checking Bolts For Stretching (Necking):

3. The Cylinder head bolts are torqued using the torque yield method, they should be examined BEFORE reuse. If the threads are necked down, the bolts should be replaced Fig. 33.
4. Necking can be checked by holding a scale or straight edge against the threads. If all the threads do not contact the scale the bolt should be replaced.

Fig. 34 Cylinder Head Tightening Sequence:

5. Tighten the cylinder head bolts 1 thorough 8 in the sequence shown in Fig. 34. Using the 4 step torque turn method, tighten according to the following values:
^ First - All to 61 Nm (45 ft.lbs.)
^ Second - All to 88 Nm (65 ft.lbs.)
^ Third - All (again) to 88 Nm (65 ft.lbs.)
^ Fourth + 1/4 Turn Do not use a torque wrench for this step.

NOTE: Bolt torque after 1/4 turn should be over 122 Nm (90 ft.lbs.). If not, replace the bolt.

6. Tighten head bolt number 9 Fig. 34 to 33 Nm (25 ft.lbs.) after head bolts 1 thorough 8 have been tighten to specifications.
7. Inspect push rods and replace worn or bent rods.

Fig. 35 Rocker Arm Shaft Retainers:

8. Install push rods, rocker arm and shaft assemblies with the stamped steel retainers in the four positions, tighten to 28 Nm (250 in.lbs.) Fig. 35.
9. Place new cylinder head cover gaskets in position and install cylinder head covers. Tighten to 12 Nm (105 in.lbs.).
10. Install intake manifold, Refer to Engine/Intake Manifold/Service and Repair.
Service and Repair

11. Install exhaust manifolds and tighten bolts to 27 Nm (20 ft. lb.) and nuts to 20 Nm (15 ft.lbs.).
12. Adjust spark plugs to specification in Powertrain Management/Powertrain Management/Spark Plug/Specifications, and install the plugs.
Specifications