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.
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.

Fig. 5 Cylinder Head Installation:

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. Connect oil sending unit lead wires.
8. Install cam belt tensioner spring stop to the cylinder head.






9. Position cam belt tensioner and tensioner spring to cylinder head, and install retaining bolts. Rotate tensioner against spring with Camshaft Belt Tensioner Tool T74P-6254-A, or equivalent. Tighten the 10 mm (25/64 inch) bolt to 38-54 Nm (28-40 ft lb) and tighten the 8 mm (5/16 inch) bolt to 19-29 Nm (14-21 ft lb).

Exhaust Manifold Tightening Sequence:

10. Install the eight exhaust manifold retaining bolts. Tighten the bolts in sequence, in two steps:
a. Step 1. 20-23 Nm (15-17 ft lb).
b. Step 2. 27-40.5 Nm (20-30 ft lb).
11. Align distributor rotor with number one plug location in the distributor cap.

Timing Compoments And Timing Mark Alignment:

12. Align cam sprocket with pointer.
13. Align crank pulley (TDC) with pointer on cam belt cover.
14. Install cam belt over sprockets.
15. Loosen tensioner retaining bolts, rotate engine and check timing alignment.
16. Tighten tensioner retaining bolts.
17. Install cam belt cover and four retaining bolts.
18. Install rocker arm cover and retaining bolts and tighten to 7-11 Nm (5-8 ft lb).

Lower Intake Manifold Bolt Tightening Sequence:

19. Position intake manifold to head, and install retaining bolts. Tighten the bolts in sequence in two steps:
a. Step 1. 15-17 Nm (11-12.5 ft lb)
b. Step 2. 19-28 Nm (14-21 ft lb).
20. Connect upper radiator hose to engine and radiator.
21. Position alternator bracket to cylinder head and install retainers.
22. Position drive belt to pulley and adjust belt tensioner.
23. Install dipstick tube to intake manifold with one bolt.
24. Install spark plugs.
25. Install dipstick.
26. Connect appropriate vacuum hoses.
27. Position and connect spark plug wires and distributor.
28. Install the retaining heater hose screw to the rocker cover.
29. Fill cooling system.
30. Install hose from air cleaner to throttle body.
31. Start engine and check for leaks.
32. Adjust ignition timing.
33. Install air cleaner.