Installation (1.6L)
- Position new (2-piece) exhaust gasket on cylinder head with heavy gasket installed first. Install exhaust manifold to head. Install intake manifold to head using new gasket. Tighten all manifold nuts to specification. See TORQUE SPECIFICATIONS table at end of article.NOTE: Ensure coolant passage openings in gasket align with manifold and cylinder head.
- Ensure gasket surfaces of head and block are clean of old gasket and sealant. Place new head gasket on cylinder block. Carefully, place cylinder head on block. Tighten cylinder head in sequence and in two stages to correct specification. See Fig 1.
- Install intake manifold support upper retaining bolts and tighten to specification. See TORQUE SPECIFICATIONS table at end of article. Install timing belt and covers. Install cam cover. On non-turbo engines, connect front exhaust pipe to exhaust manifold. Tighten nuts to specification.
- On turbocharged engines, install exhaust manifold and turbocharger assembly. Install ground wire and strap to cylinder head with retaining bolts. Connect intercooler tubes (if equipped). Connect O2 sensor connector, and install ground wires to bracket on cylinder head with retaining screw. Connect main engine harness connector. Connect fuel lines to fuel filter and pressure regulator. Install throttle cable and retaining brackets.
- Install coolant hoses and vacuum lines to intake manifold and throttle body. Install coolant hose to thermostat cover. Install intake air tube to air cleaner. Install spark plug wires and retainers. Install intake air tube to throttle body, and connect by-pass hoses. Fill cooling system. Connect negative battery terminal. Start engine, check for leaks and system operation.