1. Clean cover mounting rails on cylinder head with brake or contact cleaner and shop towels. This product will remove residue from 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 bolts and studs (Figure 2-34). Tighten cover fasteners evenly to 13-25 lb-ft (18-34 N.m) torque (Figure 2-35).
6. Remove protective covering from injectors and lines. Then connect lines to pump and injectors. 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.
8. Install fuel injector line clamps and harness and sensor brackets on manifold studs. Tighten retaining nuts to 26 lb-ft (35 N.m) torque.
9. Attach oil dipstick and tube to cover bracket.
10. Attach water control valve bracket to manifold.
11. Install and connect fuel pump.
12. Connect radiator upper hoses and inlet tube.
13. Refill engine cooling system.
14. Install air inlet hose and air horn.
15. Start engine and check cover for leaks. Then bleed each injector by loosening fuel line fitting (at injector), just enough to purge trapped air. Stop engine when complete.
16. Install engine cover and console.
17. Top engine coolant and oil levels if required.
