Installing
NOTE: Special Tools Required: 5034.Installing Cylinder Head:
CHECK BASIC SETTINGS:
1. Check position of crankshaft and camshaft:
- No. 1 piston is at TDC.
- Camshaft is at TDC firing for No. 1 cylinder.
2. Position head gasket and cylinder head.
3. Make sure 0-ring for coolant pump sits correctly in groove.
CAUTION: Do not rotate crankshaft or camshaft. Pistons may strike valves.
Early Type Cylinder Head Bolt:
Cylinder Head Bolt:
Cylinder Head Torque Sequence:
INSTALL CYLINDER HEAD BOLTS:
CAUTION: Two types of head bolts are in use. Do not interchange different types.
Early Type Head Bolts:
1. Oil head bolts.
2. Torque each bolt in sequence and in following stages:
1 = 60 Nm (43 ft lbs)
2 = 110 Nm (80 ft lbs)
NOTE: Retorque early type head bolts after engine warm up.
Late Type Head Bolts:
1. Oil head bolts.
- Replace bolts if center section shows sign of extension.
- Do not reuse bolts more than 5 times.
- If in doubt, replace bolts.
2. Torque each bolt in sequence and in following stages:
1 = 20 Nm (14 ft lbs)
2 = 60 Nm (43 ft lbs)
3 = Angle-tighten 90°
Camshaft Pulley:
Timing Belt Alignment Marks:
Timing Belt With Tensioner:
INSTALL TIMING BELT COMPONENTS:
1. Install camshaft gear and spacer washer.
- use counterhold tool 5034.
CAUTION: Do not turn crankshaft or camshaft. Pistons can strike valves and cause damage.
4. Check that camshaft, intermediate shaft and crankshaft are aligned according to markings.
5. Set rotor towards mark on distributor.
6. Place belt around crankshaft and intermediate shaft pulley so that two lines on belt align with timing mark on crankshaft.
7. Stretch belt and place it over camshaft pulley and belt tensioner.
8. Check that timing belt is correctly positioned.
- Gear markings should be opposite marking on engine and rotor opposite marking on distributor.
9. Rotate engine clockwise until at top dead center.
10. Slacken belt tensioner nut approx. one turn.
- Spring will now tension timing belt.
11. Retighten tensioner nut.
12. Install timing gear cover:
Checking Valve Clearance:
CHECK VALVE CLEARANCES.
1. If not adjusted during cylinder head overhaul, see valve adjustment procedure.
Valve Cover & Gasket:
INSTALL EXTERNAL CYLINDER HEAD COMPONENTS:
1. Install valve cover and gasket.
- check that half-moon shaped seal at rear of cylinder head is in position.
2. Install all other parts to cylinder head and intake manifold.
FINAL CHECKS/ADJUSTMENTS:
1. Warm up engine:
2. Check/adjust ignition timing, idle speed and CO content.
3. Check cooling system for leakage. Refill as necessary.
4. Turn off engine.
5. Adjust timing belt tension:
- Remove rubber plug in timing gear cover.
- Rotate engine until at top dead center.
- Slacken belt tensioner nut.
- Spring will tension timing belt.
- Tighten timing belt tensioner nut.
- Install rubber plug.
NOTE: After driving approx. 1.000 km (600 miles): Readjust timing gear belt tension.
Cylinder Head Torque Sequence:
Retorque Cylinder Head Bolts:
NOTE: This applies to early type head bolts only.
1. Warm up engine.
2. Let cool for 30 minutes.
3. Slacken head bolt #1 approx. 30°.
4. Retorque to 110 Nm (80 ft lbs).
5. Repeat for remaining bolts in sequence.