REASSEMBLY CHECKLIST -- HEAD GASKET REPLACEMENT
¨ Install New Head Gasket. Right side up! No sealant.
¨ Install Exhaust Sealing Rings. In cross-over flanges. (see step 27)
¨ Install Head/Headers. Position head with the headers attached.
¨ Install Header to Cross-over bolts. Align and insert bolts. Don't torque yet.
¨ Torque Head Nuts. (See step 43, figure 5)
¨ Torque Exhaust to Cross-over Bolts. 15 ft. lbs. (see step 27)
¨ Install Front Water Passage Head Bolts. 15 ft. lbs. (see step 42, figure 5)
¨ Replace Rear Coolant Neck and CV Bracket. 14 ft. lbs. (Step 41, figure 4)
¨ Replace Thermal Switch and its Vacuum Lines. (Step 41, figure 4)
¨ Replace Cycling Valve and its Hoses. (Step 41, figure 4)
¨ Replace Mount for Front Coolant Neck. 15 ft. lbs. (step 40, figure 1)
¨ Replace Front Coolant Neck on Mount. 15 ft. lbs. (step 40, figure 1)
¨ Replace Front Coolant Pipe and Hoses. 7 ft lbs. (Step 39, figure 1)
¨ Install Cam Tower Gasket. Right side up! No sealant. (see figure 5)
¨ Apply Assembly Lube to Lifers. (see step 38)
¨ Confirm Motor is still at TDC No.1.
¨ Install Cam Tower with Cam Gear Mark Set to TDC. 15 ft. lbs. (see step 38)
¨ Install Front Timing Cover/Cam Tower Bolts. 6 ft. lbs. (see step 35)
¨ Replace Six Cam Tower Access Plugs. 29 ft. lbs. (see step 34, figure 2)
¨ Install New Oil Filter. (see step 33)
¨ Put Back Power Steering Reservoir. (see step 32)
¨ Re-attach Co2 Test Port. (see step 31)
¨ Re-attach Electronic Test Port to Cam Tower Hoist Bracket. (see step 30)
¨ Set Timing Belt Tension. (see step 29)
¨ Install Distributor Mounting Cover. 6 ft. lbs. (see step 26)
¨ Install Timing Belt Covers. 6 ft. lbs. (see step 26)
¨ Install Heater Pipe and Hoses. (see step 35)
¨ Reinstall Accessory Belts. (see step 25)
¨ Position Intake Gaskets. (line up injector notches; No.1 goes on upside down)
¨ Position Intake with Dip Stick and Fuel Rail Attached.
¨ Install 8 Intake Bolts. 15 ft. lbs. (ensure gaskets are in place)
¨ Tighten Perch Bolt at Front of Intake. (see step 22, figure 1)
¨ Re-attach O2 Connection Bracket. (see step 21)
¨ Install Allen-bolts at Rear of Intake. (see step 20, figure 3)
¨ Re-attach Vacuum line under Throttle Body. (see step 19)
¨ Install Fuel Rail to Can Tower Bolts. 6 ft. lbs. (see step 18, figure 2)
¨ Re-connect Injector Wires/Replace Plastic Cover. (see step 17, figure 2)
¨ Re-attach Fuel Lines. (see step 16, figure 2)
¨ Re-attach Vacuum Lines to FPR and Damper. (see step 15, figure 2)
¨ Re-install Vacuum Fitting Lines on Intake. 7 ft. lbs. (see step 14, figure 2)
¨ Re-install Vacuum Hoses Between Runners. (see step 13, figure 1 and 3)
¨ Re-connect Throttle Position Sensor Connector. (see step 12, figure 1)
¨ Re-install/Adjust Throttle Cable. (see step 11, figure 1)
¨ Re-install/Adjust Cruise Control Cable. (see step 10, figure 1)
¨ Re-install Distributor Cap and Wires.
¨ Re-install I/C pipes and Coupler Hoses. (see step 8, figure 1)
¨ Re-install Boost Bolt in I/C Pipe. (see step 8, figure 1)
¨ Re-connect Hose from I/C to BOV. (see step 8, figure 1)
¨ Re-install Air Filter Box and Air Flow Meter. (see step 7)
¨ Refill Oil.
¨ Refill Coolant/Vent.
¨ Re-connect Battery.
¨ Start Car -- Check for Fuel or Coolant Leaks.
¨ Replace Belly Pans.
¨ Lower Car.
¨
Drive it like you stole it.