1. Clean cover mounting surface of cylinder head with brake or contact cleaner and shop towels. This product will remove residue from the surface and ensure proper adhesion of new sealer.
2. If new rocker arm cover is being installed, clean seal surface with brake or contact cleaner.
3. Apply sealer to rocker arm cover sealing surface. Make sealer bead 3/16 in. wide by 1/16 in. thick. Use Loctite 599, Permatex Ultra Copper, or similar quality silicone sealer. Allow sealer to cure slightly (skin over) before installation.
4. Align and install rocker arm cover on cylinder head.
5. Install rocker arm cover attaching studs and bolts (Figure 2-34). Tighten cover fasteners evenly to 13-25 lb-ft (18-34 N.m) torque. Start at center and work toward ends when tightening.
6. Remove protective covering from injectors and lines.
Then connect lines to injectors and to pump, if removed. Tighten line fittings to 20-22 lb-ft (27-30 N.m) torque.
7. Install intake manifold and new gaskets. A gasket dressing such as, perfect seal, or Permatex High Tack, can be used to hold gaskets in place. Tighten manifold bolts and studs to 31 lb-ft (42 N.m) torque in sequence (Figure 2-35).
8. Install fuel injector line clamps and wire harness brackets on manifold studs. Tighten retaining nuts to 26 lb-ft (35 N.m) torque.
9. Install CDR valve and hose.
10. Install bolt that secures transmission fill tube to cylinder head.
11. Install water control valve and hoses.
12. Install surge tank.
13. Refill cooling system
14. Start engine and check cover for leaks. Then bleed each injector by loosening fuel line fitting (at injector), just enough to purge any trapped air. Stop engine when complete.
15. Install air cleaner, inlet hose, and air horn.
16. Install engine cover and front console.
17. Top off engine coolant and oil levels if required.
