Installation
INSTALLATION OF CYLINDER HEADS1. INSTALL CYLINDER HEADS
A. Place cylinder head on cylinder block
(a) Place a new cylinder head gasket in position on the cylinder block.
NOTE: Be careful of the installation direction.
(b) Place the cylinder head in position on the cylinder head gasket.
B. Install cylinder head (12 pointed head) bolts
NOTE: The cylinder head bolts are tightened in three progressive steps (steps (b), (d) and (e)). If any bolts is broken or deformed, replace it.
(a) Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
(b) Install and uniformly tighten the cylinder head bolts in several passes in the sequence shown.
- Torque: 350 kg-cm (25 ft-lb, 34 N.m) If any one of the bolts does not meet the torque specification, replace the bolt.
(c) Mark the front of the cylinder head bolt head with paint.
(d) Retighten the cylinder head bolts 90° in the numerical order shown.
(e) Retighten cylinder head bolts by an additional 90°.
(f) Check that the painted mark is now facing rearward.
C. Install cylinder head (recessed head) bolts
(a) Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
(b) Using a 8 mm hexagon wrench, install the cylinder head bolts.
- Torque: 185 kg-cm (13 ft-lb. 18 N.m)
2. INSTALL LH ENGINE HANGER
- Torque: 380 kg-cm (27 ft-lb, 37 N.m)
3. ASSEMBLE EXHAUST CAMSHAFTS
(a) Install the following parts:
(1) Camshaft gear spring
(2) Camshaft sub-gear
(3) Wave washer
(b) Using snap ring pliers, install the snap ring.
(c) Mount the hexagonal wrench head portion of the camshaft in a vise.
NOTE: Be careful not to damage the camshaft.
(d) Insert a service bolt (A) into the service hole of the camshaft sub-gear.
(e) Using a screwdriver, align the holes of the camshaft driven gear and sub-gear by turning camshaft sub- gear clockwise, and install a service bolt (B).
NOTE: Be careful not to damage the camshaft.
4. INSTALL CAMSHAFTS
NOTE: Since the thrust clearance of the camshaft is small, the camshaft must be held level while it is being installed. If the camshaft is not level the portion of the cylinder head receiving the shaft thrust may crack or be damaged causing the camshaft to seize or break. To avoid this, the following steps should be carried out.
A. Install intake camshaft of RH cylinder head
(a) Apply MP grease to the thrust portion of the camshaft.
Fig. 15 Intake Cam Installation:
(b) Place the intake camshaft at 90° angle of timing mark (two pointed marks) on the cylinder head.
Fig. 16 No. 1 Cam Cap Sealing Location:
(c) Apply seal packing to the No.1 bearing cap as shown. Seal packing: Part No.08826-00080 or equivalent
(d) Install the five bearing caps in their proper locations.
(e) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
(f) Install and uniformly tighten the ten bearing cap bolts in several passes in the sequence shown.
- Torque: 160 kg-cm (12 ft-lb, 16 N.m)
B. Install exhaust camshaft of RH cylinder head
(a) Apply MP grease to the thrust portion of the camshaft.
(b) Align the timing marks (two pointed marks) of the camshaft drive and driven gears.
(c) Place the exhaust camshaft on the cylinder head.
(d) Install the four bearing caps in their proper locations.
(e) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
(f) Install and uniformly tighten the eight bearing cap bolts in several passes in the sequence shown.
- Torque: 160 kg-cm (12 ft-lb, 16 N.m)
(g) Remove the service bolt (B).
C. Install intake camshaft of LH cylinder head
(a) Apply MP grease to the thrust portion of the camshaft.
(b) Place the intake camshaft at 90° angle of timing mark (one pointed mark) on the cylinder head.
Fig. 16 No. 1 Cam Cap Sealing Location:
(c) Apply seal packing to the No.1 bearing cap as shown. Seal packing: Part No. 08826-00C80 or equivalent
(d) Install the five bearing caps in their proper locations.
(e) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
(f) Install and uniformly tighten the ten bearing cap bolts in several passes in the sequence shown.
- Torque: 160 kg-cm (12 ft-lb, 16 N.m)
D. Install exhaust camshaft of LH cylinder head
(a) Apply MP grease to the thrust portion of the camshaft.
(b) Align the timing marks (one pointed mark) of the camshaft drive and driven gears.
(c) Place the intake camshaft on the cylinder head.
(d) Install the four bearing caps in their proper locations.
(e) Apply a light coat of engine oil on the threads and under the heads of bearing cap bolts.
(f) Install and uniformly tighten the eight bearing cap bolts in several passes in the sequence shown.
- Torque: 160 kg-cm (12 ft-lb. 16 N.m)
(g) Remove the service bolt (B).
5. CHECK AND ADJUST VALVE CLEARANCE
- Turn the camshaft and position the cam lobe upward, and check and adjust the valve clearance.
Valve clearance (Cold):
Intake 0.13-0.23 mm (0.005 - 0.009 in.)
Exhaust 0.27-0.37 mm (0.011 - 0.015 in.)
6. INSTALL CAMSHAFT OIL SEALS
(a) Apply MP grease to a new oil seal lip.
(b) Using SST, tap in the oil seals. SST 09223-46011
7. INSTALL SPARK PLUG TUBE GASKETS
- Install the six lube gaskets.
8. INSTALL CYLINDER HEAD COVERS
(a) Apply seal packing to the cylinder heads as shown in the figure. Seal packing: Part No.08826-00080 or equivalent
(b) Install the gasket to the cylinder head cover.
(c) Install the cylinder head cover with the six seal washers and nuts. Uniformly tighten the nuts in several passes. Install the two cylinder head covers.
- Torque: 60 kg-cm (52 in.lb, 5.9 N.m)
9. INSTALL NO.3 TIMING BELT COVER
- Install the timing belt cover with the six bolts.
- Torque: 75 kg-cm (65 in.lb, 7.4 N.m)
10. INSTALL NO.2 IDLER PULLEY, CAMSHAFT TIMING PULLEYS AND TIMING BELT Service and Repair
11. INSTALL SPARK PLUGS
- Torque: 180 kg-cm (13 ft-lb. 18 N.m)
12. INSTALL RH EXHAUST MANIFOLD
(a) Install the inside heat insulator with the bolt.
(b) Install a new gasket and the exhaust manifold with six new nuts. Uniformly tighten the nuts in several passes.
- Torque: 400 kg-cm (29 ft-lb, 39 N.m)
(c) Install the outside heat insulator with the three nuts.
(d) Connect the oxygen sensor connector.
13. INSTALL LH EXHAUST MANIFOLD
(a) Install a new gasket and the exhaust manifold with six new nuts. Uniformly tighten the nuts in several passes.
- Torque: 400 kg-cm (29 ft-lb, 39 N.m)
(b) Install the heat insulator with the two nuts.
14. INSTALL INTAKE MANIFOLD
(a) Install two new gaskets and the intake manifold with the eight bolts and four nuts. Uniformly tighten the bolts and nuts in several passes.
- Torque: 180 kg-cm (13 ft-lb, 18 N.m)
(b) Install the No.2 idler pulley bracket stay with the two bolts.
- Torque: 185 kg-cm (13 ft-lb, 18 N.m)
15. INSTALL CYLINDER HEAD REAR PLATE
- Install the rear plate with the two bolts.
16. INSTALL WATER BY-PASS OUTLET
(a) Install the crossover pipe heat insulator with the two bolts.
(b) Install a new gasket and the water by-pass outlet with the three nuts.
- Torque: 200 kg-cm (14 ft-lb, 20 N.m)
(c) Connect the following connectors and hose:
(1) Heater water by-pass hose
(2) Cold start injector time switch connector
(3) Water temperature sensor connector
17. INSTALL WATER OUTLET
(a) Install a new gasket and the water outlet with the three nuts.
- Torque: 85 kg-cm (73 in.-lb. 8.3 N.m)
(b) Connect the following hose and connector:
(1) Radiator upper hose
(2) Water temperature switch connector
18. INSTALL INJECTORS AND DELIVERY PIPES
19. INSTALL AIR INTAKE CHAMBER
Fig. 10 Intake Manifold Removal:
(a) Install two new gaskets and the intake chamber with the two bolts and two nuts. Uniformly tighten the bolts and nuts in several passes.
- Torque: 440 kg-cm (32 ft-lb, 43 N.m)
(b) Install the two intake chamber stays with the four bolts.
- Torque: 380 kg-cm (27 ft-lb, 37 N.m)
(c) Connect the following hoses:
(1) PCV hose
(2) Vacuum sensing hose
(3) EGR gas temperature sensor connector (CALIF. only)
(4) A/C control valve air hose
20. INSTALL COLD START INJECTOR TUBE
21. CONNECT COLD START INJECTOR CONNECTOR
22. INSTALL EXHAUST CROSSOVER PIPE
(a) Install new two gaskets to the RH and LH exhaust manifolds.
(b) Install the crossover pipe with the six nuts and two bolts.
- Torque: Nut 400 kg-cm (29 ft-lb, 39 N.m)
- Bolt 350 kg-cm (25 ft-lb, 34 N.m)
23. INSTALL DISTRIBUTOR
24. INSTALL VACUUM PIPE
(a) Install the vacuum pipe with the two bolts.
(b) Connect the following hoses:
(1) Four BVSV vacuum hoses
(2) A/C control valve vacuum hose
25. INSTALL EGR VALVE AND VACUUM MODULATOR
(a) Install a new gasket and the EGR valve and vacuum modulator with the two bolts and two nuts.
- Torque: 185 kg-cm (13 ft-lb, 18 N.m)
(b) Install the four vacuum pipe hoses.
26. INSTALL EGR PIPE
- Install a new gasket and the EGR pipe with the two bolts and union nut.
- Torque: Bolt 185 kg-cm (13 ft-lb, 18 N.m)
- Nut 800 kg-cm (58 ft-lb, 78 N.m)
27. INSTALL THROTTLE BODY
28. INSTALL ISC VALVE
29. INSTALL ALTERNATOR
30. INSTALL FRONT EXHAUST PIPE
31. INSTALL RH ENGINE UNDER COVER
32. INSTALL AIR CLEANER HOSE
33. INSTALL CRUISE CONTROL ACTUATOR
34. INSTALL ACCELERATOR CABLE, AND ADJUST IT
35. CONNECT THROTTLE CABLE, AND ADJUST IT (A/T)
36. INSTALL SUSPENSION UPPER BRACE
37. FILL WITH ENGINE COOLANT
38. CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY
39. START ENGINE AND CHECK FOR LEAKS
40. ADJUST IGNITION TIMING
- Ignition timing: 10 BTDC @ idle (w/ Terminals TE1 and E1 connected)
41. PERFORM ROAD TEST
- Check for abnormal noise, shock, slippage, correct shift points and smooth operation.
42. RECHECK ENGINE COOLANT LEVEL AND OIL LEVEL