This document provides a detailed guide on how to properly install O-rings for 6.5L cylinder blocks, ensuring a reliable seal and optimal engine performance. Follow the steps outlined below to achieve the best results.

Before beginning the installation process, it is essential to prepare the cylinder deck and gather the necessary tools.

1. Coat the cylinder block deck with Dykem layout dye or use a sharpie to color around every cylinder.

2. Place the head gasket on the cylinder block and scribe the head gasket bores onto the block.

To ensure the best seal around the cylinder, it is crucial to avoid all water passages and bolt holes. Typically, the groove will be cut ¼” larger than the bore. It is recommended to position the O-ring ⅛” outside the edge of the head gasket fire ring.

Once the diameter is established, the next step is to set the depth of the groove.

1. Using four .025 feeler gauges (or cut one into four pieces), place each feeler gauge under the pins that the cutting tool sits on. Loosen the blade's lock screw, push the blade down until it contacts the block, and then lock it back down. It is advisable to cut all but one cylinder, allowing for a reference point if you need to reset the cutting blade.

2. Tech Tip: Allow the tool to do the work; do not apply excessive pressure, as this may cause the cutting blade to slip, resulting in an incorrect depth.

After cutting seven of the eight cylinders, you have two options:

• Use a .005 feeler gauge on a cylinder you have already rough cut to achieve a total depth of .030.

• Utilize the uncut cylinder to set up with a .030 feeler gauge, which is the method typically recommended.

The simplest way to set the depth is to cut the feeler gauges into four pieces (both .025 and .030) and place them between the block surface and the aluminum cat-paw pins. Then, set the cutting tool flush with the block surface and lock it down.

Once all grooves are cut and cleaned out, it is time to install the wire. It is crucial to use a plastic hammer gently to tap the supplied .040 wire into the groove. If struck too hard, the wire may deform, compromising the seal.

Gently tap the wire into the groove all the way around the circle. Once you determine how much wire you need, cut it ½” longer than anticipated. Just before completing the circle, cut the excess so that the ends butt up with no gap or overlap.

The cutting blade of the groove-o-matic is .038” wide, ensuring that the .040” copper wire fits snugly in the groove. The wire should protrude .010-.015” above the block surface when properly installed.

By following these steps, you can ensure a proper installation of O-rings for cylinder heads, leading to enhanced engine performance and reliability.