Installation

*** THIS ARTICLE REFLECTS CHANGES MADE BY TSB #94-18-10, DATED September 07, 1994

INSTALLATION

NOTE: The engine should always be assembled using new cylinder head bolts.

Cylinder Head And Gaskets:

1. Position cylinder head gaskets on cylinder block. Install cylinder head locating dowels. Position the cylinder heads onto the head gaskets and locating dowels.

NOTE: The cylinder heads and intake manifold are torqued alternately and in sequence to make sure of correct fit and gasket crush.

Cylinder Head Bolt Tightening Sequence:

2. Install and tighten cylinder head bolts, in the sequence shown, to 30 Nm (22 lb ft).

Intake Manifold And Gasket:

3. Apply Silicone Sealer (Loctite 598, F1AZ-19562-A or equivalent) to the block and cylinder head mating surfaces at the four corners shown. Install the intake manifold gasket and again apply sealer to the four corner locations.

NOTE: Once applied, the silicone sealer will set up in approximately 15 minutes. The intake manifold must be installed immediately after the sealer is applied.

Lower Intake Manifold Bolt Tightening Sequence:

4. Position the intake manifold on the two guide studs and install the nuts and bolts hand-tight. Tighten the intake manifold bolts in sequence to 4-8 Nm (3-6 ft lb).
5. Tighten the cylinder head bolts in sequence to 70 Nm (52 lb ft).
6. Tighten the intake manifold to 8-15 Nm (6-11 ft lb).
7. Rotate the cylinder head bolts 90 degrees tighter in sequence for the final cylinder head torque step.
8. Finish tightening the intake manifold in sequence to 15-21 Nm (11-15 ft lb) and then to 21-25 Nm (15-18 ft lb).
9. Install valve push rods. Install rocker arms and tighten rocker arm stand bolts to 32 Nm (24 ft lb) plus an additional 90 degrees.
10. Apply Silicone Rubber D6AZ-19562-BA (ESB-M4G92-A and ESE-M4G195-A) or equivalent to the four locations at the joint where the intake manifold and the cylinder heads meet.
11. Install valve covers and tighten bolts to 6-8 Nm (4.5-5.9 ft lb), and two minutes later tighten screws to same specification.
12. Install the upper intake manifold and tighten the nuts to 20-25 Nm (15-18 ft lb).
13. Install air conditioner compressor on bracket and screw retaining air conditioner manifold tube to upper intake manifold. Tighten compressor bolts to 21-29 Nm (16-21 ft lb).
14. Install the exhaust inlet pipe and R.H. exhaust manifold and L.H. exhaust manifold.
15. Install the spark plugs.
16. Install the ignition coil and assembled ignition coil mounting strap.
17. Install the alternator.
18. Install drive belt over pulleys. Make sure that all V-grooves make proper contact with pulleys.
19. Lift tensioner and slide drive belt under drive belt tensioner. Release tensioner to rest pulley on drive belt.
20. Install the A/C compressor mounting bracket with assembled power steering pump to the cylinder heads.
21. Install the A/C compressor.
22. Fill and bleed the cooling system.
23. Connect the battery ground cable at the battery.

NOTE: 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.