Cylinder Head Assembly & Installation
FIGURE 24:
Cylinder Head Assembly
1. Lightly lubricate the valve stems, guides and seals with engine oil.
2. Assemble and install the valves, valve springs, spring seats, retainers and keepers in the cylinder head (Fig. 24).
FIGURE 22:
3. Install the valve tappets (50) and shims (51) (Fig. 22).
4. Lubricate the camshaft journals and the journal bores in the cylinder head with engine oil.
FIGURE 29:
5. Install the camshaft in the cylinder head. Position the cam so the sprocket keyway
(65) is facing upward. This will help align the cam timing marks during assembly.
6. Install the camshaft bearing caps but do not install the cap bolts at this time. Align and position the caps according to the reference marks made at disassembly.
NOTE: The bearing caps are numbered 1 through 5. Install the caps in numerical sequence starting with cap 5 which goes at the cam sprocket end of the head.
7. Install and tighten the camshaft bearing cap bolts as follows:
Apply a drop of Loctite 242 to the threads of each bolt and install the bolts finger tight.
FIGURE 30:
Tighten each bolt to an initial torque of 10 N-m (88 in.lbs.) in the sequence shown in Figure 30.
Final tighten bolts 1-10 to 20 N-m (15 ft.lbs.) torque.
Retighten bolts 11-12 to 10 N-m (88 in.lbs) torque.
FIGURE 31A:
FIGURE 31B:
8. Lubricate the replacement camshaft oil seals with engine oil. Then install the front seal with tool Mot. 988.01 and the rear seal with tool Mot. 1010 (Fig. 31).
FIGURE 19:
9. Install the timing belt cover mounting plate (46), the mounting plate bolts (45) and the camshaft sprocket key (44) (Fig. 19).
FIGURE 18:
10. Install the sprocket (42) on the camshaft (Fig. 18).
11. Hold the camshaft sprocket with tool Mot. 855 and install the sprocket bolt (43). Tighten the bolt to 50 N-m (37 ft.lbs.) torque (Fig. 18).
12. Rotate the camshaft sprocket until the timing marks on the sprocket and cover mounting plate are aligned.
13. Install a replacement rotor as follows:
Wipe the rotor bore and camshaft clean with paper towels.
Apply a small amount of Loctite RC 680 adhesive to the rotor bore surfaces.
Install and hold the replacement rotor firmly in position on the camshaft for a minimum of 15 seconds. Be sure the rotor is fully seated on the camshaft.
Allow the adhesive to cure and harden for at least 30 minutes before operating the engine.
FIGURE 32:
14. Install a replacement manifold gasket on the cylinder head and install the intake and exhaust manifolds. Tighten the manifold attaching guts in the sequence shown in Figure 32.
Tightening torques are: Tighten nuts 1-10 to 22 N-m (16 ft.lbs.). Tighten nut 11 to 40 N-m (30 ft.lbs.). Tighten bolts 12 and 13 to 22 N-m (16 ft.lbs.) torque.
Cylinder Head Installation
1. Remove the tape covering the oil feed hole in the block and remove the shop towels from the cylinder bores.
2. Check the bolt threads in the cylinder block. The threads must be clean and dry. Run a tap or a head bolt in and out of the bolt holes if necessary.
3. Wipe the gasket surface of the block clean and position the replacement head gasket on the block.
FIGURE 7:
4. Check alignment of the timing mark (13) on the crankshaft sprocket (Fig. 7). The timing mark should be aligned with the pan bolt (14). Rotate the crankshaft to align the timing mark and bolt if necessary.
5. Check alignment of the timing marks on the camshaft sprocket and cover mounting plate. Turn the cam sprocket to align the marks if necessary.
FIGURE 33:
6. Install the assembled cylinder head and manifold on the block. Be sure the head is properly seated on the locating dowels (66) in the block (Fig. 33).
FIGURE 34:
7. Lubricate the cylinder head bolt threads and the underside of the bolt heads with engine oil.
8. Install and tighten the cylinder head bolts only as described in the following procedure:
a. Tighten the head bolts in the sequence shown in Figure 34. Use wrench tool Mot. 852, or an equivalent to tighten the bolts.
b. Tighten the bolts to an initial torque of 30 N-m (22 ft.lbs.).
c. Tighten the bolts a second time to 70 N-m (52 ft.lbs.) torque.
d. Wait three or four minutes-then-completely loosen all the bolts.
e. Tighten the bolts to 20 N-m (15 ft.lbs.) torque.
FIGURE 35:
f. Attach the degree wheel of angular wrench tool Mot. 591.03 to socket wrench tool Mot. 852 (Fig. 35).
g. Mount the flexible pointer of tool Mot.
591.03 on the head. Then align the tool pointer with the degree wheel on the socket wrench (Fig. 35).
h. Final tighten the head bolts an additional 123 degrees, plus or minus 2 degrees, while observing the degree wheel and pointer.
9. Install the timing belt as follows:
a. If the original belt is being installed, refer to the paint marks placed on the belt at disassembly.
FIGURE 36:
Align the "cam" paint mark (67) with the timing marks on the cam sprocket (68) and cover mounting plate (69) (Fig. 36).
FIGURE 9:
Check alignment of the belt lower timing mark. The lower paint mark (17) should be aligned with the timing mark (18) on the crankshaft sprocket (Fig.9).
FIGURE 37:
b. If a new timing belt is being installed, install the belt so the belt mark (70) nearest the directional arrows is aligned with the marks on the cam sprocket (71) and mounting plate (72) (Fig. 37).
The two directional arrows (73) on the belt should be between the intermediate shaft pulley (74) and idler pulley (75) (Fig. 37).
FIGURE 37:
The lower mark on the new belt should be aligned with the crankshaft sprocket timing mark as shown in Figure 9.
FIGURE 38:
10. Adjust timing belt tension with deflection gauge set Ele. 346.04.
Position the gauge bar on the belt span between the idler and intermediate shaft pulleys (Fig, 38). Then push the gauge plunger inward until it contacts the belt.
Turn the tensioner pulley adjusting nut (76) clockwise to decrease deflection or counterclockwise to increase deflection.
Belt tension is correct when deflection of the gauge tool is a maximum of 7.5 mm (0.295 in).
11. Remove the Mot. 861 top dead center tool from the crankshaft and block.
12. Verify that the engine is correctly timed. Rotate the crankshaft two complete revolutions. Reinstall the Mot. 861 TDC tool in the crankshaft timing slot.
Now verify that the timing marks on the belt, cam sprocket, cover mounting plate and crankshaft sprocket are aligned.
13. Recheck and adjust timing belt tension if necessary.
14. Remove the Mot. 861 top dead center tool and install the plug in the cylinder block TDC access hole.
15. Install the cylinder head cover.
16. Connect the fuel injector connector, fuel lines, heat riser tube and coolant hoses.
17. Connect the coolant temperature, TPS, idle speed motor, MAT and MAP sensor, and the WOT switch connectors.
18. Install the distributor cap.
19. Clean the bolt threads in the crankshaft and the threads of the crankshaft pulley bolt.
20. Install the pulley on the crankshaft.
21. Apply two drops of Loctite 271 to the crankshaft pulley bolt threads and install the bolt. Tighten the bolt to 95 N-m (70 ft.lbs.) torque.
22. Tighten the A/C compressor mounting bracket bolts to 38 N-m (928 ft.lbs.) torque.
23. Install and adjust the accessory drive belt as outlined in the August 1986, edition of the M.R. 245 manual.
CAUTION: The belt must be installed as described in the manual. An incorrectly installed belt can turn the water pump in the wrong direction resulting in overheating.
24. Install the splash shield in the front passenger side wheel well.
25. Raise the vehicle, connect the exhaust pipes and lower the vehicle.
26. Install the air cleaner and fill and bleed the cooling system.