Installation

*** THIS ARTICLE REFLECTS CHANGES MADE BY TSB 94-6-4 DATED March 23, 1994 ***

INSTALLATION

CAUTION: The new design cylinder head gasket and cylinder head bolts are uniquely different from the production and previously designed parts. Because of this difference, the new cylinder head bolts (F3ZZ-6065-A) are the only bolts that can be used with the new cylinder head gasket (F3ZZ-6051-C). If a previously released cylinder head gasket is to be used, or if cylinder head bolts are not available for use with the new head gasket (F3ZZ-6051-C), the previously released cylinder head gasket and cylinder head bolts must be used. Failure to properly torque the cylinder head gasket can lead to an improper sealing surface, which can result in a leaking condition and broken bolts.

1. Position head gasket on the block.
2. Clean rocker arm cover (cam cover).
3. Install rocker cover gasket to the rocker cover.

Timing Pointer Locations:

4. With the camshaft in the proper position, install the cylinder head onto the cylinder head gasket.

CAUTION: The camshaft used with this engine must be properly positioned as shown to ensure proper timing alignment.

5. Install all ten (10) cylinder head bolts (F3ZZ-6065-A) into the cylinder block, finger tight.

Cylinder Head Torque Sequence:

6. Use the new "Torque Plus Angle" procedure as follows only for the new head gasket and new bolts.
a. Tighten all ten (10) cylinder head bolts in the sequence shown to 70 Nm (51 lb ft).
b. Retighten all ten (10) cylinder head bolts in the sequence shown to 70 Nm (51 lb ft).
c. Tighten all ten (10) cylinder head bolts in the sequence shown an additional 90-100°.
7. Position intake manifold to head, and install retaining bolts.
8. Connect engine wiring harnesses.
9. Install timing belt idler spring stop to the cylinder head.
10. Position timing belt idler to cylinder head, and install retaining bolts.

Exhaust Manifold Installation:

11. Install the eight exhaust manifold retaining bolts and/or stud bolts and tighten in sequence in two steps:
a. Step 1. 20-23 Nm (15-17 ft lb)
b. Step 2. 27-45 Nm (20-33 ft lb)
12. Install four nuts and/or stud bolts retaining heat stove to exhaust manifold.
13. Align cam gear with pointer.
14. Align crank pulley (TDC) with pointer on cam belt cover.
15. Position timing belt to pulleys (cam and auxiliary).
16. Loosen idler retaining bolts, rotate engine and check timing alignment.
17. Adjust belt tensioner and tighten retaining bolts.
18. Install timing belt cover and retaining bolt.
19. Connect upper radiator hose to engine and radiator and tighten retaining clamps.
20. Position alternator bracket to cylinder head and install retainers.
21. Position drive belt to pulley and adjust belt tension using Belt Tension Gauge Rotunda 021-00045 or equivalent.
22. Install rocker arm cover and retaining bolts.
23. Install spark plugs.
24. Install dipstick tube and bracket.
25. Connect appropriate vacuum hoses.
26. Position and connect spark plug wires.
27. Install two retaining heater/hose screws to the rocker cover.
28. Fill cooling system.
29. Start engine and check for leaks.
30. Install air cleaner hose to throttle body.