Installation
WARNING:Fire Hazard
Do not smoke or carry lighted tobacco or an open flame of any type when working on or near any fuel related components. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury
CAUTION:
Cleaning Aluminum Surfaces
Do not use abrasive grinding discs to remove gasket material; use only plastic manual scrapers. Do not scratch or gouge aluminum sealing surfaces.
1. Clean all gasket material from the mating surfaces on the cylinder head and cylinder block (6010). Clean out the bolt holes in the cylinder block. Inspect the cylinder head for flatness.
2. Install a new head gasket on the cylinder block.
CAUTION:
Injury Hazard
Do not attempt to install the cylinder head assembly without assistance. Installation of the cylinder head assembly requires two persons.
Torque-To-Yield Bolts
Always use new cylinder head bolts.
NOTE: Lubricate the cylinder head bolts with engine oil prior to installation.
3. Install the cylinder head assembly and torque the cylinder head bolts in the following sequence.
A) Torque all the bolts in a single sequence to 40-60 Nm (30-44 ft. lbs.).
B) Back the bolts off 1/2 turn.
C) Retorque the bolts in the sequence shown to 40-60 Nm (30-44 ft. lbs.).
D) Rotate all the bolts in a single sequence an additional 180° in two steps of 90° each.
4. Install the uppermost front engine accessory drive bracket bolt and tighten to 40-55 Nm (29.5-40.5 ft. lbs.).
5. Install the A/C line bracket on the front engine accessory drive bracket and tighten to 20-25 Nm (15-18 ft. lbs.).
6. Install the valve cover and gasket. Tighten bolts to 8-11.5 Nm (70-101 inch lbs.).
7. Raise and support the vehicle.
8. Tighten the four front engine accessory drive bracket bolts and one nut to 40-55 Nm (29.5-40.5 ft. lbs.).
9. Remove the wire support and install the A/C compressor and four bolts. Tighten bolts to 20-30 Nm (15-22 ft. lbs.).
10. Close the radiator petcock.
11. Install the RH splash shield assembly and tighten bolts to 7.8-11 Nm (69-98 inch lbs.).
12. Install the oil level indicator tube.
13. Lower the vehicle.
14. Install the heater hose.
15. Install the upper radiator hose.
16. Install the timing belt.
17. Install the generator (3).
A) Pivot into position.
B) Install upper bolt (2) and tighten to 40-55 Nm (29-40 ft. lbs.).
C) Tighten lower bolt (1) to 20-30 Nm (15-22 ft. lbs.).
18. Install the power steering pressure hose (B) to the front engine accessory drive bracket. Tighten bolts (A) to 7.8-10.8 Nm (64-87 inch lbs.).
19. Connect the CKP sensor electrical connector.
20. Connect the two main engine/fuel charging wiring electrical connectors.
21. Install the oil level indicator tube bolt and tighten to 8-11.5 Nm (70-101 inch lbs.).
22. Install the EGR manifold tube at the EGR valve and tighten nut to 20-28 Nm (15-21 ft. lbs.).
23. Install the EGR valve manifold tube to the exhaust manifold and tighten nuts to 5-7 Nm (45-62 inch lbs.).
WARNING:
Fire Hazard
Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury
24. Connect the fuel supply line to the fuel injection supply manifold.
25. Connect the fuel return line to the fuel injection supply manifold.
26. Install the four exhaust manifold-to-three way catalytic converter (TWC) nuts and tighten to 34-47 Nm (26-34 ft. lbs.).
27. Install the exhaust manifold heat shield and tighten nuts to 5-7 Nm 945-61 inch lbs.).
28. Install the speed control cable bracket and tighten bolts to7.8-10.8 Nm (64-87 inch lbs.).
29. Connect the (A) speed control cable, the (B) accelerator cable, and the (C) throttle valve control actuating cable to the throttle control lever.
30. Install the vacuum hoses at the (A) EGR valve, the (B) positive crankcase ventilation (PCV) valve, the (C) throttle body, the (D) fuel pressure regulator, and the (E) intake manifold.
31. Install the outlet half of the engine air cleaner and the air cleaner intake tube. Refer to Powertrain Management.
32. Fill with coolant. Refer to Cooling System.
33. Connect the battery ground cable and tighten to 7-10 Nm (62-88 inch lbs.).