Installation

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

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

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 valley. If the cylinder head was removed for a head gasket replacement, check the flatness of the cylinder head and block gasket surfaces.

NOTE: Replace alignment dowels if damaged.

Positioning Cylinder Head Gasket:

2. Position head gaskets on cylinder block using the dowels for alignment. Make sure gasket is aligned as shown in the illustration.
3. Carefully position cylinder heads on cylinder 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).

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

7. Re-tighten 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).
8. Install intake manifold.

CAUTION: If a new distributor is installed, be sure to add the rest of the pint of Engine Assembly Lubricant D9AZ-19579-D (ESR-M99C80-A) or equivalent to the engine oil by pouring it through the distributor hole onto the cam drive gear. Run engine at Idle for five minutes before driving vehicle.

9. Dip entire distributor drive gear in Engine Assembly Lubricant D9AZ-19579-D (ESR-M99C80-A) or equivalent.
10. If a new distributor, pour the rest of the pint of Engine Assembly Lubricant D9AZ-19579-D (ESR-M99C80-A) or equivalent through distributor hole onto cam drive gear.
11. Install distributor and align to premarked location on cylinder block and rotor position. Install retaining bolt and washer finger-tight.
12. Connect spark plug wire sets to spark plugs.
13. Dip each push rod in Engine Assembly Lubricant D9AZ-19579-D (ESR-M99C80-A) or equivalent heavy engine oil. Install push rods in their original position and orientation.

Camshaft Position A - Rocker Arm, Push Rod, And Fulcrum Installation:

14. Rotate engine so camshaft is in Position A, as shown, with camshaft sprocket timing mark and crankshaft sprocket timing mark at TOP CENTER.

NOTE: Lubricate each push rod, rocker arm, and rocker arm fulcrum with Engine Assembly Lubricant D9AZ-19579-D (ESR-M99C80-A) or other heavy engine oil before installing.

15. Install push rod, rocker arm, rocker arm fulcrum, and rocker arm bolt for valves:
a. Cylinder No. 1 Intake.
b. Cylinder No. 2 Exhaust.
c. Cylinder No. 4 Intake.
d. Cylinder No. 5 Exhaust.
Tighten rocker arm bolts to 11 N.m (8 ft-lb).
16. For valves in above step, check rocker arm-to-valve clearance. Clearance should be 2.15-4.69mm (0.084-0.184 in.).

Camshaft Position B - Rocker Arm, Push Rod, And Fulcrum Installation:

17. Rotate engine so camshaft is in Position B, as shown, with camshaft sprocket timing mark at TWO O'CLOCK position and crankshaft sprocket timing mark at 4:30 position.

NOTE: Lubricate each push rod, rocker arm, and rocker arm fulcrum with Engine Assembly Lubricant D9AZ-19579-D (ESR-M99C80-A) or other heavy engine oil before installing.

18. Install push rod, rocker arm, rocker arm fulcrum, and rocker arm bolt for valves:
a. Cylinder No. 1 Exhaust.
b. Cylinder No. 2 Intake.
c. Cylinder No. 3 Exhaust.
d. Cylinder No. 3 Intake.
e. Cylinder No. 4 Exhaust.
f. Cylinder No. 5 Intake.
g. Cylinder No. 6 Exhaust.
h. Cylinder No. 6 Intake.
19. For valves in above step, check rocker arm-to-valve clearance. Clearance should be 2.15-4.69mm (0.084-0.184 in.).

Rocker Arm Fulcrum Must Be Fully Seated:

CAUTION: Rocker arm fulcrum must be fully seated into cylinder head and push rod must be fully seated into lifter sockets before final tightening.

20. Final-tighten rocker arm nuts to 32 N.m (24 ft-lb) with camshaft in any position.

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.

21. Apply Engine Assembly Lubricant D9AZ-19579-D (ESR-M99C80-A) to all rocker arm assemblies.
22. Install exhaust manifolds. 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 Tube Into Block:

23. Apply Cup Plug Sealer ESE-M4G2 17-A or equivalent to cylinder block. Install oil level indicator tube into cylinder block. Dipstick tube must bottom out as illustrated. Tighten retaining nut to 18N-m (13 ft-lb).
24. Install spark plugs. Tighten to 11 N.m (8 ft-lb).
25. Install valve covers.
26. Install fuel charging wiring to fuel injectors and inboard rocker arm cover studs. Connect fuel charging wiring to engine control sensor wiring and secure with retaining features.
27. Install throttle body and new intake manifold upper gasket.
28. Install coil and bracket assembly and bracket. Tighten retaining nuts to 18 N.m (13 ft-lb). Connect electrical connection to ignition coil.
29. 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 power steering pump support. Tighten three retaining bolts and one nut to 51 N-m (38 ft-lb).
c. Install drive belt.
30. If right cylinder head was removed, perform the following:
a. Install PCV closure hose from rocker arm cover oil fill adapter to engine air cleaner.
b. Install generator and generator bracket assembly. Tighten 3 retaining bolts to 48 N.m (35 ft-lb).
c. Install generator brace and tighten nuts to 26-35 N.m (20-25 ft-lb).
d. Install drive belt.
e. Connect generator voltage regulator wiring.
31. Position the A/C hose and manifold assembly in engine compartment with hoses vented as originally with no kinks or binds.
32. Remove all caps and plugs. Push suction hose into coupling on accumulator and liquid line into coupling on condenser.
33. Position hose assembly manifold to A/C compressor and install retaining bolt. Tighten to 25-30 N.m (18-22 ft-lb).
34. Evacuate and recharge air conditioning system.
35. Connect fuel lines to fuel injection supply manifold. Install fuel tube clips.
36. Connect upper radiator hose and heater water hoses. Tighten hose clamps securely.
37. Connect vacuum lines to premarked locations.

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

38. Drain and change engine oil.
39. Install air cleaner outlet tube to throttle body and engine air cleaner. Tighten clamps securely.

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

40. Fill and bleed cooling system.

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.

41. Connect battery ground cable.
42. Start engine and check for coolant, fuel, oil, vacuum and exhaust leaks.
43. Verify base ignition timing.
44. Check and, if necessary, adjust speed control linkage.