Installing

NOTE: Special Tools Required: 5034.

Installing Cylinder Head:

CHECK BASIC SETTINGS:
1. Check position of crankshaft and camshaft:
- No. 1 piston is at TDC.
- Camshaft is at TDC firing for No. 1 cylinder.
2. Position head gasket and cylinder head.
3. Make sure 0-ring for coolant pump sits correctly in groove.

CAUTION: Do not rotate crankshaft or camshaft. Pistons may strike valves.

Cylinder Head Bolt:

Cylinder Head Torque Sequence:

INSTALL CYLINDER HEAD BOLTS:
1. Oil head bolts.
- Replace bolts if center section shows sign of extension.
- Do not reuse bolts more than 5 times.
- If in doubt, replace bolts.
2. Torque each bolt in sequence and in following stages:

1 = 20 Nm (14 ft lbs)
2 = 60 Nm (43 ft lbs)
3 = Angle-tighten 90°

Camshaft Pulley:

Timing Belt Tensioner Stud:

Timing Gear Belt Upper Cover:

INSTALL TIMING BELT COMPONENTS:
1. Install camshaft gear and spacer washer.
- use counterhold tool 5034.
2. Install stud bolt for belt tensioner.
3. Install belt tensioner, washer and nut.

CAUTION: Do not turn crankshaft or camshaft. Pistons can strike valves and cause damage.

4. Set timing gears in positions according to marking.
5. Set rotor towards mark on distributor.
6. Place belt around crankshaft gear and intermediate shaft gear.
7. Stretch belt and place it over camshaft gear and belt tensioner.
8. Remove 3 mm drill from belt tensioner.
9. Check that timing belt is correctly positioned.
- Gear markings should be opposite marking on engine and rotor opposite marking on distributor.
10. Rotate engine clockwise until at top dead center.
11. Slacken belt tensioner nut approx. one turn.
- Spring will now tension timing belt.
12. Retighten tensioner nut.
13. Install upper timing gear cover:
1 10mm socket M 6 bolt
2 12mm socket M 8 bolt
3 Phillips screwdriver sheet metal screw

Checking Valve Clearance:

CHECK VALVE CLEARANCES.
1. If not adjusted during cylinder head overhaul, see valve adjustment procedure.

Valve Cover & Gasket:

INSTALL EXTERNAL CYLINDER HEAD COMPONENTS:
1. Install valve cover and gasket.
2. Install distributor:
- position distributor on cylinder head.
- turn rotor while pressing distributor againist cylinder head. Turn until distributor shaft aligns with camshaft recess.
3. Install distributor hold down bolt.
4. Install distributor cap.
5. Connect ground lead.
6. Install all other parts to cylinder head and intake manifold.




FINAL CHECKS/ADJUSTMENTS:
1. Warm up engine:
2. Check/adjust ignition timing, idle speed and CO content.
3. Check cooling system for leakage. Refill as necessary.
4. Turn off engine.
5. Adjust timing belt tension:
- Remove rubber plug in timing gear cover.
- Rotate engine until at top dead center.
- Slacken belt tensioner nut.
- Spring will tension timing belt.
- Tighten timing belt tensioner nut.
- Install rubber plug.

NOTE: After driving approx. 1.000 km (600 miles): Readjust timing gear belt tension.