Installation

NOTE: Lightly oil all bolt and threads before installation. Always use new bolts when installing a cylinder head.

1. Lay a clean shop rag in lifter valley to catch any gasket particles. Clean cylinder head, intake manifold and cylinder head to block gasket surfaces. After scraping, lift cloth so no gasket material falls into lifter holes. If the cylinder head was removed for a cylinder head gasket replacement, check the flatness of the cylinder head and block gasket surfaces.

CAUTION: Gouges in aluminum components will cause gaskets to leak.

Positioning Cylinder Head Gasket:

2. Position new head gasket(s) on cylinder block using the dowels for alignment. Make sure gasket is aligned as shown in the illustration.

NOTE: Replace alignment dowels if damaged.

3. Carefully position cylinder head(s) on block.
4. Install new cylinder head retaining bolts and hand tighten.

Cylinder Head Assembly, Installation:

5. Tighten retaining bolts in sequence as illustrated to 80 N.m (59 ft-lb).
6. Back off all bolts a MINIMUM of one full turn (360 degrees).
7. Retighten the cylinder head retaining bolts in sequence in two tightening steps as follows:
a. 50 N.m (37 ft-lb).
b. 92 N.m (68 ft-lb).

NOTE: When the cylinder head retaining bolts have been tightened using the above procedure, it is not necessary to retighten the bolts after extended engine operation. However, the bolts can be checked for tightness if desired.

8. Install intake manifold.
9. Completely coat distributor gear teeth with ESP-M2C154-A or equivalent heavy-weight gear lube. Install distributor and align to premarked location on cylinder block and rotor position. Install retaining bolt and washer and hand-snug. Connect ignition wires to spark plugs.

NOTE: Do not add any of the ESP-M2C154-A directly to the engine oil.

10. Dip each push rod in Oil Conditioner D9AZ-19579-CA (ESR-M99C80-A) or equivalent heavy engine oil. Install push rods in their original position.

Installation-Rocker Arm, Push Rod And Fulcrums:

11. Rotate camshaft to position A as shown. Install rocker arms, fulcrums and retaining bolts in locations specified in camshaft position A. Tighten bolts to 11 N.m (8 ft-lb) to seat fulcrums in cylinder head. Rotate crankshaft 120 degrees to position B. Install rocker arms, fulcrums and retaining bolts in locations specified in camshaft position B. Tighten bolts to 11 N.m (8 ft-lb).
12. Final-tighten retaining bolts to 32 N.m (24 ft-lb) with camshaft in any position.

CAUTION: Fulcrums must be fully seated in cylinder head and push rods must be fully seated in rocker arm sockets and tappets prior to final tightening.

13. Apply Oil Conditioner D9AZ-19579-CA (ESR-M99C80-A) to all rocker arm assemblies.

NOTE: If the original valve train components are being installed, a valve clearance check is not required. If a component has been replaced, perform a valve clearance check.

14. Install exhaust manifold(s). Tighten retaining bolts to 25 N.m (18 ft-lb). Install inlet pipe retaining nuts. Tighten to 41 N.m (30 ft-lb).

Installing Dipstick Into Block:

15. Install dipstick tube into cylinder block as illustrated. Tighten retaining nut to 18 N.m (13 ft-lb).
16. Install spark plugs. Tighten to 11 N.m (8 ft-lb).
17. Install rocker arm covers.
18. Install fuel injector electrical harness to injectors and inboard rocker arm cover studs. Connect engine harness to main harness and secure with retaining features.
19. Install throttle body and new gasket as outlined.
20. Install ignition control module and bracket. Tighten retaining nuts to 18 N.m (13 ft-lb). Connect electrical connection to ignition control module.
21. If left cylinder head was removed, perform the following:
a. Install fuel line retaining bracket to front of cylinder head. Tighten retaining bolt to 35 N.m (26 ft-lb).
b. Install power steering pump and bracket assembly. Tighten three retaining bolts and one nut to 51 N.m (38 ft-lb).
c. Install accessory drive belt.
22. If right cylinder head was removed, perform the following:
a. Install closure hose from rocker arm cover oil fill adapter to air cleaner.
b. Install alternator and bracket assembly. Tighten 3 retaining bolts to 48 N.m (35 ft-lb).
c. Install accessory drive belt.
d. Connect alternator electrical harness.
23. Connect fuel lines to fuel supply rail. Install fuel line safety clips.
24. Connect upper radiator and heater hoses. Tighten clamps securely.
25. Connect vacuum lines to premarked locations.
26. Drain and change engine oil.

NOTE: Engine coolant is corrosive to all engine bearing material. Replacing engine oil after removal of a coolant carrying component prevents failure later.

27. Install clean air flex tube to throttle body and air cleaner. Tighten clamps securely.
28. Fill and bleed cooling system.

CAUTION: This engine has aluminum components and requires a special corrosion inhibited coolant formulation to avoid radiator damage.

29. Connect negative battery cable.

NOTE: On vehicles equipped with EEC, when the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy.

30. Start engine and check for coolant, fuel, oil, vacuum and exhaust leaks.
31. Verify base ignition timing.
32. Check and, if necessary, adjust speed control linkage.