Installation

Cylinder Head Assembly:

INSTALLATION

1. Clean and inspect cylinder head and engine block surfaces.
2. Install new head gasket with TOP side UP. Align gasket with dowels.
3. Lubricate head bolt threads with light oil. Carefully guide cylinder head over chain/sprocket and onto block. Make sure that head aligns with dowels in engine block.
4. Install head bolts and torque "finger tight" only.

Top Timing Cover Bolts:

5. Install two top timing cover bolts at the front of the cylinder head. DO NOT torque.

Head Bolt Torque Sequence:

6. Torque cylinder head bolts in proper sequence in two stages.

STAGE 1 - 61.5 ft.lbs. (8.5 kg-m)
STAGE 2 - 72.0 ft. lbs. (10.0 kg-m)

7. Tighten two top timing cover bolts at the front of the cylinder head.

Camshaft Alignment:

8. Install camshaft with index mark facing UP.
9. Install rocker shaft assembly with punch mark (A) facing UP.

Rocker Arm Springs:

10. Install rocker arm springs.
11. Torque rocker arm assembly nuts to:

15.2 - 16.6 ft.lbs. (2.1 - 2.3 kg-m)

Timing Mark Alignment:

12. Align camshaft index mark with line on rocker shaft bracket.
13. Align crankshaft pulley mark to "0" on timing cover.
14. Install timing sprocket and chain on camshaft.

Camshaft Bolt Torque:

15. Install camshaft bolt and torque to:

50.6 - 65.0 ft.lbs. (7.0 - 9.0 kg-m)

16. Slowly turn engine clock-wise by HAND two full revolutions to ensure that valves do not hit pistons.

Automatic Adjuster Reset:

17. Set automatic adjuster by turning slide pin 90 degrees with a screwdriver.
18. Adjust valves.

Rubber Plug:

19. Apply sealer to arched side of rubber plug and install in cylinder head. Re-install rocker cover with new gasket.
20. Re-install intake and exhaust manifolds. (Refer to ENGINE MECHANICAL; INTAKE MANIFOLD REPLACEMENT, EXHAUST MANIFOLD REPLACEMENT).
21. Re-fill cooling system with proper concentration of water/anti-freeze.
22. Re-connect battery ground. Start engine and warm up to operating temperature.
23. Check for leaks and repair as necessary.