Part 1

CYLINDER HEAD

COMPONENTS:

COMPONENTS:

COMPONENTS:

COMPONENTS:

COMPONENTS:

COMPONENTS:

COMPONENTS:

COMPONENTS:

COMPONENTS:

COMPONENTS:

COMPONENTS:

INSTALLATION (STEPS 1-35)





1. INSPECT CYLINDER HEAD SET BOLT
a. Using vernier calipers, measure the tension portion diameter of the bolt.
Standard outside diameter: 8.95 to 9.05 mm (0.3524 to 0.3563 inch)
Minimum outside diameter: 8.75 mm (0.3445 inch)
If the diameter is less than the minimum, replace the bolt.





2. INSTALL CYLINDER HEAD GASKET NO. 2
a. Place a new cylinder head gasket on the cylinder block with the L mark upward.

NOTICE:
^ Remove any oil from the contact surface.
^ Be careful to install the gasket in the correct direction.
^ Place the cylinder head on the gasket carefully in order not to damage the gasket at the bottom part of the head.

3. INSTALL CYLINDER HEAD LH

NOTICE: The cylinder head bolts are tightened in 2 successive steps.

a. Apply a light coat of engine oil to the threads of the cylinder head bolts.
b. Install the plate washer to the cylinder head bolt.





c. Using several steps, install and tighten the 8 cylinder head bolts uniformly in the sequence shown in the illustration.
SST 09011-38121
Torque: 54 Nm (550 kgf-cm, 40 ft. lbs.)





d. Mark the front side of each cylinder head bolt head with paint as shown in the illustration.
e. Retighten the cylinder head bolts by 90° in the same sequence as step (C).
f. Check that each painted mark is now at 90° angle to the front.





g. Using a socket hexagon wrench 8 mm, install the hexagon bolt.
Torque: 19 Nm (189 kgf-cm, 14 ft. lbs.)





h. Using several steps, install and tighten the 2 bolts and intake air connector bracket No. 2 uniformly in the sequence shown in the illustration.
Torque: 7.0 Nm (71 kgf-cm, 62 inch lbs.)
i. Connect the ground cable with the 2 bolts.
Torque:
Nut A 8.4 Nm (85 kgf-cm, 74 inch lbs.)
Nut B 11 Nm (112 kgf-cm, 97 inch lbs.)
4. INSTALL NO. 4 CAMSHAFT SUB-ASSEMBLY
5. INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY
6. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
7. INSTALL WATER INLET PIPE
8. INSTALL OIL LEVEL GAUGE GUIDE
a. Install a new O-ring to the oil level gauge guide.
b. Apply soapy water to the O-ring.
c. Push in the oil level gauge guide end into the guide hole of the cylinder block.





d. Install the oil level gauge guide with the bolt.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
e. Install the oil level gauge.





9. INSTALL EXHAUST MANIFOLD CONVERTER SUB ASSEMBLY NO. 2
a. Install a new gasket as shown in the illustration.





b. Install the exhaust manifold converter No. 2 with the 6 nuts and bolt. Using several steps, tighten the nuts uniformly in the sequence shown in the illustration.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
c. Retighten nuts 1 and 2 shown in the illustration.
10. CONNECT COOLING FAN ECU
a. Connect the 2 bolts and cooling fan ECU.
Torque: 2.6 Nm (26 kgf-cm, 23 inch lbs.)





11. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 2
a. Install the 2 bolts and exhaust manifold heat insulator No. 2.
Torque: 8.5 Nm (87 kgf-cm, 75 inch lbs.)





12. INSTALL MANIFOLD CONVERTER INSULATOR NO. 3
a. Install the bolt, nut and manifold converter insulator No. 3.
Torque: 8.5 Nm (87 kgf-cm, 75 inch lbs.)





13. INSTALL CYLINDER HEAD GASKET
a. Place a new cylinder head gasket on the cylinder block with the R mark upward.

NOTICE:
^ Remove any oil from the contact surface.
^ Be careful to install the gasket in the correct direction.
^ Place the cylinder head on the gasket carefully in order not to damage the gasket at the bottom part of the head.

14. INSTALL CYLINDER HEAD SUB-ASSEMBLY

NOTICE: The cylinder head bolts are tightened in 2 successive steps.

a. Apply a light coat of engine oil to the threads of the cylinder head bolts.
b. Install the plate washers to the cylinder head bolts.





c. Using several steps, install and tighten the 8 cylinder head bolts uniformly in the sequence shown in the illustration.
SST 09011-38121
Torque: 54 Nm (550 kgf-cm, 40 ft. lbs.)





d. Mark the front side of each cylinder head bolt head with paint as shown in the illustration.
e. Retighten the cylinder head bolts by 90° in the same sequence as step (C).
f. Check that each painted mark is now at 90° angle to the front.





g. Using a socket hexagon wrench 8 mm, install the hexagon bolt.
Torque: 19 Nm (189 kgf-cm, 14 ft. lbs.)
h. Connect the engine wire harness clamp with the nut.
Torque: 8.4 Nm (85 kgf-cm, 74 inch lbs.)
15. INSTALL NO. 2 CAMSHAFT
16. INSTALL CAMSHAFT
17. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
18. INSTALL IGNITION COIL ASSEMBLY
Torque: 8.0 Nm (80 kgf-cm, 71 inch lbs.)





19. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
a. Install a new gasket as shown in the illustration.





b. Install a new gasket and the exhaust manifold RH with the 6 nuts. Using several steps, tighten the nuts uniformly in the sequence shown in the illustration.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
c. Retighten nuts 1 and 2 shown in the illustration.
20. INSTALL MANIFOLD STAY
a. Temporarily install the manifold stay to the exhaust manifold and transaxle.
b. Fully tighten the 2 bolts.
Torque: 34 Nm (347 kgf-cm, 25 ft. lbs.)





21. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 1
a. Install the 3 bolts and exhaust manifold heat insulator No. 1.
Torque: 8.5 Nm (87 kgf-cm, 75 inch lbs.)
22. INSTALL EXHAUST PIPE SUB-ASSEMBLY FRONT NO. 3
23. INSTALL EXHAUST PIPE ASSEMBLY FRONT
24. INSTALL TIMING BELT NO. 3 COVER
25. INSTALL CAMSHAFT TIMING PULLEY
26. INSTALL TIMING BELT IDLER SUB-ASSEMBLY NO. 2
27. INSPECT TIMING BELT
28. INSTALL TIMING BELT
29. INSTALL CHAIN TENSIONER ASSEMBLY NO. 1
30. INSTALL TIMING BELT GUIDE NO. 2
31. INSTALL ENGINE MOUNTING BRACKET RH
32. INSTALL TIMING BELT NO. 2 COVER
33. INSTALL TIMING BELT NO. 1 COVER
34. INSTALL CRANKSHAFT PULLEY
35. INSTALL ENGINE MOUNTING STAY NO. 2 RH