Installation Procedure
| Required Tools | |||
| Tool | Part Number | Part Description | Qty |
| A (1) | 9U-6198 | Crankshaft Turning Tool | 1 |
| A (2) | 5P-7306 | Housing | 1 |
| 5P-7305 | Engine Turning Tool | 1 | |
| B | 136-4632 | Engine Timing Pin | 1 |
| C | 298-5564 | T40 Torx Socket | 1 |
| D | 227-4389 | E10 Torx Socket | 1 |
| E | 370-4657 | Rocker Arm Spacer | 6 |
| ( 1 ) | The Crankshaft Turning Tool is used on the front pulley. |
| ( 2 ) | This Tool is used in the aperture for the electric starting motor. |
Note: Either Tooling (A) can be used. Use the Tooling that is most suitable.
| NOTICE |
|---|
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
- Clean valve bridges (6) . Inspect the valve bridges for wear and damage. Replace any valve bridges that are worn or damaged.
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| Illustration 1 | g02004077 |
The correct location of valve bridges on valve stems is shown. | |
- Lubricate valve bridges (6) with clean engine oil.
- Install valve bridges (6) to the valve stems.
Note: Install used valve bridges in the original location and in the original orientation. Ensure that the valve bridges are correctly seated on the valves. New valve bridges may be installed in either orientation.
| NOTICE |
|---|
Failure to ensure that ALL valve bridges are correctly seated onto the valve stems will cause interference between the pistons and the valves, resulting in damage to the engine. |
- Clean the pushrods. Inspect the pushrods for wear and damage. Replace any pushrods that are worn or damaged.
 | |
| Illustration 2 | g02004093 |
- Apply clean engine oil to both ends of the pushrods. Install the pushrods to the engine with the cup upward.
Note: Ensure that the pushrods are installed in the original location and that the ball end of each pushrod is correctly seated in the valve lifters.
- If necessary, use Tooling (A) in order to rotate the crankshaft so that number one piston is at top dead center on the compression stroke. Refer to System Operation, Testing and Adjusting, "Position the Valve Mechanism Before Maintenance Procedures" for the correct procedure. Install Tooling (B) through Hole (W) in order to lock the crankshaft.
Note: Do not use excessive force to install Tooling (B) . Do not use Tooling (B) to hold the crankshaft during repairs.
 | |
| Illustration 3 | g02085993 |
- Remove Tooling (B) .
- Use Tooling (A) in order to rotate the crankshaft in a clockwise direction and position the crankshaft at 60 degrees after top dead center.
| NOTICE |
|---|
Failure to ensure that the crankshaft is positioned at 60 degrees after top dead center will result in interference between the pistons and the valves. Failure to ensure that the crankshaft is positioned at 60 degrees after top dead center will result in damage to the engine. |
- Ensure that the rocker shaft assembly is clean and free from wear and damage.
 | |
| Illustration 4 | g02003035 |
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| Illustration 5 | g02307257 |
- Position the rockershaft assembly with Spotfaces (Y) for Torx screws (7) in the up ward position.
- Install Tooling (E) to rocker shaft assembly.
- Install Torx screws (7) to the rocker shaft.
Note: Ensure that correct Torx screw (7) is installed to Position (X) .
- Ensure that ALL threaded inserts are fully unscrewed. Position rocker shaft assembly (8) onto the cylinder head. The retaining clip (10) should face the front of the engine.
Note: Ensure that the threaded inserts are correctly seated in ends of pushrods (9) .
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| Illustration 6 | g02004078 |
 | |
| Illustration 7 | g02003036 |
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| Illustration 8 | g02047334 |
- Use Tooling (D) in order to tighten Torx screws (7) hand tight.
- Remove Tooling (E) from the rocker shaft. Install the remaining Torx screws (7) to the rocker shaft. Tighten the Torx screws (7) hand tight.
- Tighten the Torx screws to a torque of 35 N·m (26 lb ft) in the numerical sequence that is shown in Illustration 8.
- Ensure that valve bridges (6) are correctly located on the valve stems.
- Ensure that guides (5) for the pushrods are correctly positioned on threaded inserts (4) . Use Tooling (C) in order to tighten threaded inserts (4) on all the rocker arms. Tighten the threaded inserts to a torque of 30 N·m (265 lb in).
Note: When the threaded insert is tightened, the threaded insert must seat correctly into the cup for the pushrod.
 | |
| Illustration 9 | g01992077 |
- Install a new O-ring seal (1) to plug (2) . Install the plug into Hole (W) in the cylinder block. Tighten plug (2) to a torque of 21 N·m (186 lb in).
 | |
| Illustration 10 | g01992076 |
- The engine should not be operated for a period 30 minutes after the threaded inserts on all the rocker arms have been tightened. This period will allow the force of the valve springs to purge off excessive engine oil from the hydraulic lifters.
End By: Install the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install" for the correct procedure.