Installation

INSTALLATION OF CYLINDER HEADS

1. INSTALL CYLINDER HEADS

A. Place cylinder heads on cylinder block

(a) Place two new cylinder head gaskets in position on the cylinder block.

NOTE: On the rear side of the cylinder head gasket are painted marks to distinguish the LH and RH banks, a white painted mark for the RH bank and a yellow painted mark for the LH bank. Be careful of the installation direction.

(b) Place the two cylinder heads in position on the cylinder head gaskets.

B. Install cylinder head bolts

NOTE: The cylinder head bolts are tightened in two progressive steps. If any cylinder head bolt 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) Temporarily install the twenty plate washers and cylinder head bolts.

(c) Uniformly tighten the ten cylinder head bolts on one side of each cylinder head in several passes in the sequence shown, then do the other side as shown.

Torque: 400 kg-cm (29 ft-lb, 39 N.m)
- If any one of the bolts does not meet the torque specification, replace the bolt.

(d) Mark the front of the cylinder head bolt head with paint.
(e) Retighten the cylinder head bolts 90° in the numerical order shown.
(f) Check that the painted mark is now at a 90° angle to front.

C. Install engine wire to cylinder heads

Install the clamps and ground straps of the engine wire as shown.

2. INSTALL CIRCULAR PLUGS

(a) Place two new circular plugs in position on the cylinder heads, facing the cup side forward.
(b) Remove any old packing (FIPG) material.

Fig. 26 Seal Packing Locations:

(d) RH Cylinder Head - Install the bearing cap (mark "I1") in position with the arrow mark facing rearward.
(e) LH Cylinder Head - Install the bearing cap (mark "I6") in position with the arrow mark facing forward.
(f) Install a new seal washer to the bearing cap bolt.
(g) Apply a light coat of engine oil on the threads of the bearing cap bolt.
(h) Install the four bearing cap bolts.

Torque: 160 kg-cm (12 ft-lb 16 N.m)

NOTE: Use silver colored bolts 38 mm (1.50 in.) in length.

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.

(d) Insert a service bolt (A) into the service hole of the camshaft sub-gear.
(e) Using a screwdriver, align the service holes and teeth of the camshaft driven gear and sub-gear by turning the camshaft sub-gear clockwise, and install a service bolt (B).

NOTE: Be careful not to damage the camshaft.

(f) Remove the service bolt (A).

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 kept 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.

(b) Place the intake camshaft at 45° angle of the timing mark (one pointed mark) on the cylinder head.
(c) Remove any old packing (FIPG) material.

(d) Apply seal packing to the bearing cap (mark "16") as shown. Seal packing: Part No.08826-00080 or equivalent

(e) Install the front bearing cap (mark "16") with the arrow mark facing rearward.

NOTE: Installing the front bearing cap will determine the thrust position of the camshaft. Align the arrow marks at the front and rear of the cylinder head with the mark on the bearing cap.

(f) Install the other bearing caps in the sequence shown with the arrow mark facing rearward.

NOTE: Align the arrow marks at the front and rear of the cylinder head with the mark on the bearing cap.

(g) Apply a light coat of engine oil on the threads and under the heads (A only) of the bearing cap bolts.

NOTE: Do not apply engine oil under the heads of the bearing cap bolts (B).

(h) Install a new seal washer to the bearing cap bolt (B). Install the eight bearing cap bolts as shown.

NOTE: Use bearing cap bolts 38 mm (1.50 in.) in length. The bolts are black (A) or silver (B) in color. Install the two silver bolts to the front bearing cap. Install the six black bolts to the other positions. After installing the oil feed pipe, install the two bolts to the rear bearing cap as directed in step B (i).

(i) Uniformly tighten the eight 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) Set the timing mark (one pointed mark) of the camshaft drive gear at 10° angle by turning the intake camshaft with a wrench.
(b) Apply MP grease to the thrust portion of the exhaust camshaft.
(c) Align the timing marks lone pointed mark) of the camshaft drive and driven gears.

(d) Place the exhaust camshaft on the cylinder head.
(e) Check that the exhaust camshaft moves smoothly in the thrust direction.

(f) Install the rear bearing cap with the arrow mark facing rearward.

NOTE: Installing the rear bearing cap will determine the thrust position of the camshaft. Align the arrow marks at the front and rear of the cylinder head with the mark on the bearing cap.

(g) Install the other bearing caps in the sequence shown with the arrow mark facing rearward.

NOTE: Align the arrow marks at the front and rear of the cylinder head with the mark on the bearing cap.

(h) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.

(i) Install the oil feed pipe and ten bolts.

NOTE: Use bearing cap bolts 38 mm 11.50 in.) and 52 mm ( 2.05 in.) in length. Use black colored 38 mm (1.50 in.) bolts. Install the two 52 mm (2.05 in.) bolts on the outside positions of the oil pipe. Install the eight 38 mm (1.50 in.) bolts on the other positions.

(j) Uniformly tighten the eight bearing cap bolts on the bearing caps of the exhaust camshaft in several passes, in the sequence shown.

Torque: 160 kg-cm (12 ft-lb. 16 N.m)

(k) Alternately tighten the two bearing cap bolts on the rear bearing cap of the intake camshaft in several passes.

Torque: 160 kg-cm (12 ft-lb, 16 N.m)

(l) Bring the service bolt installed in the driven sub-gear upward by turning the camshaft with a wrench.
(m) Remove the service bolt.

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 60° angle of the timing mark (one pointed mark) on the cylinder head.
(C) Remove any old packing (FIPG) material.

(d) Apply seal packing to the bearing cap (mark "I1") as shown. Seal packing: Part No.08826-00080 or equivalent

(e) Install the front bearing cap (mark "I1") with the arrow mark facing forward.

NOTE: Installing the front bearing cap will determine the thrust position of the camshaft. Align the arrow marks at the front and rear of the cylinder head with the mark on the bearing cap.

(f) Install the other bearing caps in the sequence shown with the arrow mark facing forward.

NOTE: Align the arrow marks at the front and rear of the cylinder head with the mark on the bearing cap.

(g) Apply a light coat of engine oil on the threads and under the heads (A only) of the bearing cap bolts.

NOTE: Do not apply engine oil under the heads of the bearing cap bolts (B).

(h) Install a new seal washer to the bearing cap and install the eight bearing cap bolts as shown.

(i) Uniformly tighten the eight 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) Set the timing mark (two dot marks) of the camshaft drive gear at 15° angle by turning the intake camshaft with a wrench.
(b) Apply MP grease to the thrust portion of the exhaust camshaft.
(c) Align the timing marks (two dot marks) of the camshaft drive and driven gears.

(d) Place the exhaust camshaft on the cylinder head.
(e) Check that the exhaust camshaft moves smoothly in the thrust direction.

(f) Install the front bearing cap with the arrow mark facing forward.

NOTE: Installing the front bearing cap will determine the thrust position of the camshaft. Align the arrow marks at the front and rear of the cylinder head with the mark on the bearing cap.

(g) Install the other bearing caps in the sequence shown with the arrow mark facing forward.

NOTE: Align the arrow marks at the front and rear of the cylinder head with the mark on the bearing cap.

(h) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
(i) Install the oil feed pipe and ten bolts.

NOTE: Use bearing cap bolts 38 mm (1.50 in.) and 52 mm (2.05 in.) in length. Use black colored 38 mm (1.50 in.) bolts. Install the two 52 mm (2.05 in.) bolts on the outside positions of the oil pipe. Install the eight 38 mm (1.50 in.) bolts on the other positions.

(j) Uniformly tighten the eight bearing cap bolts on the bearing caps of the exhaust camshaft in several passes, in the sequence shown.

Torque: 160 kg-cm (12 ft-lb, 16 N.m)

(k) Alternately tighten the two bearing cap bolts on the bearing cap of the intake camshaft second from the front in several passes.

Torque: 160 kg-cm (12 ft-lb, 16 N.m)

(l) Bring the service bolt installed in the driven sub-gear upward by turning the camshaft with a wrench.
(m) Remove the service bolt.

5. CHECK AND ADJUST VALVE CLEARANCE
- Turn the camshaft, and position the cam lobe upward, and check and adjust the valve clearance.Valve clearance:

Intake 0.15-0.25 mm (0.006 - 0.010 in.)
Exhaust 0.25-0.35 mm (0.010 - 0.014 in.)

6. INSTALL CAMSHAFT OIL SEALS

(a) Apply MP grease to a new oil seal lip.
(b) Using SST, tap in the two oil seals. SST 09223-46011

7. INSTALL SEMI-CIRCULAR PLUGS

(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the semi-circular plug groove. Seal packing: Part No.08826-00080 or equivalent
(c) Install the four semi-circular plugs.

8. INSTALL CYLINDER HEAD COVERS

(a) Remove any old packing (FIPG) material.

(b) Apply seal packing to the cylinder heads as shown in the illustration. Seal packing: Part No.08826-00080 or equivalent
(c) Install the gasket to the cylinder head cover.
(d) Install the seal washer to the bolt. Install the cylinder head cover with the eight bolts. Install the two cylinder head covers.

Torque: 60 kg-cm (52 in-lb, 5.9 N.m)

9. INSTALL ENGINE WIRE BRACKETS TO RH CYLINDER HEAD
- Install the wire bracket with the two bolts. Install the two wire brackets.

10. INSTALL ENGINE HANGERS
- Install the engine hanger with the two bolts. Install the two engine hangers.

Torque: 380 kg-cm (27 ft-lb, 37 N.m)

11. INSTALL RH EXHAUST MANIFOLD

(a) Place a new gasket on the cylinder head with the yellow painted marks facing the manifold side.

NOTE: Be careful of the installation direction.

(b) Install the exhaust manifold with the four bolts and four new nuts.

Torque: 450 kg-cm (33 ft-lb, 44 N.m)

(c) Connect the LH main oxygen sensor connector.

13. INSTALL OIL DIPSTICK AND GUIDE

(a) Install a new 0-ring to the dipstick guide.
(b) Apply a light coat of engine oil on the 0-ring.
(c) Push in the dipstick guide into the guide hole of the No.1 oil pan.
(d) Install the oil dipstick and guide with the bolt.

14. INSTALL MAIN CATALYTIC CONVERTERS
15. INSTALL FRONT EXHAUST PIPE
16. INSTALL FRONT WATER BY-PASS JOINT
- Install two new gaskets and the water by-pass joint with the four nuts.

Torque: 185 kg-cm (13 ft-lb, 18 N.m)

17. INSTALL REAR WATER BY-PASS JOINT

(a) Install the two water by-pass hoses to the water bypass joint.
(b) Install two new gaskets and the water by-pass joint with the four nuts.

Torque: 185 kg-cm (13 ft-lb, 18 N.m)

18. INSTALL INTAKE MANIFOLD

(a) Place two new gaskets on the cylinder heads with the white painted mark facing upward.

NOTE: Align the port holes of the gasket and cylinder head. Be careful of the installation direction.

(b) Place the intake manifold in position on the cylinder head with the arrow mark facing forward.

NOTE: Be careful of the installation direction.

(c) Install the six bolts and four nuts.

Torque: 185 kg-cm (13 ft-lb, 18 N.m)

NOTE: Use bolts 30 mm (1.18 in.) in length.

19. INSTALL DELIVERY PIPES AND INJECTORS

(a) Place the eight insulators and four spacers in position on the intake manifold.
(b) Place the eight injectors and two delivery pipe assemblies in position on the intake manifold.
(c) Check that the injectors rotate smoothly.

(d) Position the injector connectors upward.
(e) Install the wire bracket and four nuts.

Torque: 185 kg-cm (13 ft-lb, 18 N.m)

(f) Install the fuel return pipe with the two new gaskets, union bolt and bolt.

Torque:
Union bolt 360 kg-cm (26 ft-lb, 35 N.m)
Bolt 80 kg-cm (69 in-lb, 7.8 N.m)

(g) Connect the fuel hose (from LH delivery pipe) to the fuel tube.
(h) Connect the fuel hose to the fuel return pipe.
(i) Connect the eight injector connectors.
(j) Install the engine wire to the delivery pipes with the six bolts.
(k) Install the two connectors to the wire bracket on the LH delivery pipe.
(l) Connect the following connectors:

(1) Water temperature sensor connector
(2) Cold start injector time switch connector
(3) Water temperature sender gauge connector

20. CONNECT HEATER HOSES TO REAR WATER BY-PASS JOINT AND WATER BY-PASS PIPE
21. INSTALL ENGINE WIRE TO WIRE BRACKET ON CYLINDER HEAD
- Install the engine wire with the two bolts and clip.

22. INSTALL ENGINE WIRE TO INTAKE MANIFOLD
- Install the engine wire with the two bolts.

23. INSTALL AIR INTAKE CHAMBER

(a) Install the cold start injector, tube and wire assembly with the three bolts.

Torque: 80 kg-cm (69 in-lb. 7.8 N.m)

(b) Place four new gaskets on the air intake chamber.

NOTE: Gaskets can only be used twice before being replaced.

(c) Install four new gaskets and the air intake chamber with the four bolts and eight nuts. Install the check connector.

Torque: 185 kg-cm (13 ft-lb, 18 N.m)

NOTE: Use bolts 40 mm (1.57 in.) in length.

(d) Connect the cold start injector tube to the RH delivery pipe with the two new gaskets and the union bolt.

Torque: 150 kg-cm (11 ft-lb, 15 N.m)

(e) Connect the cold start injector connector.

24. INSTALL ACCELERATOR BRACKET
- Install the bracket with the bolt and stud bolt.

25. INSTALL BRAKE BOOSTER UNION

(a) Install the union with two new gaskets and the two bolts.

Torque: 300 kg-cm (22 ft-lb, 29 N.m)

(b) Connect the vacuum hose to union.

26. INSTALL THROTTLE BODY

(a) Place a new gasket in position on the air intake chamber.
(b) Connect the water by-pass hose (from rear water bypass joint) to the throttle body.
(c) Connect the PCV hose to the cylinder head cover, and install the throttle body with the two bolts and two nuts.

Torque: 185 kg-cm (13 ft-lb, 18 N.m)

NOTE: Use bolts 40 mm (1.57 in.) in length.

(d) Install the water by-pass pipe (from rear water by-pass joint) to the clamp on the engine wire cover.
(e) Connect the sensor connectors.

27. INSTALL ISC VALVE

(a) Connect the ISC valve connector.
(b) Install a new gasket and the ISC valve with the two nuts.

Torque: 185 kg-cm (13 ft-lb, 18 N.m)

(c) Connect the water by-pass hose (from throttle body) to the ISC valve.

28. INSTALL VACUUM PIPE

(a) Install the vacuum pipe and six vacuum hoses with the two bolts.

(b) Connect the following hoses:

(1) Vacuum hose to fuel pressure regulator
(2) Vacuum hose to upper port of EVAP BVSV
(3) Vacuum hose to air intake chamber
(4) Three vacuum hoses to throttle body

29. INSTALL EGR VALVE ADAPTOR

(a) Install a new gasket and the adaptor with the two bolts and two nuts.

Torque: 185 kg-cm (13 ft-lb, 18 N.m)

NOTE: Do not touch the air intake chamber and adapter surfaces of the gasket with your hand.

NOTE: Use bolts 20 mm (1.79 in.) in length.

(b) Connect the EGR gas temperature sensor connector.

30. INSTALL EGR VALVE AND VACUUM MODULATOR

(a) Install a new gasket, the EGR valve, vacuum and modulator assembly with the two nuts and bolt.

Torque (Nut): 185 kg-cm (13 ft-lb, 18 N.m)

NOTE: Do not touch the adaptor and EGR valve surfaces of the gasket with your hand.Align the port holes of the gasket and adaptor. Be careful of the installation direction.

(b) Connect the following hoses:

(1) Water by-pass pipe to ISC valve
(2) Water by-pass pipe to rear water by-pass joint
(3) Two vacuum hoses to vacuum pipe

31. INSTALL EGR VSV

(a) Install the VSV with the bolt.
(b) Connect the following hoses:

(1) Vacuum hose to EGR valve
(2) Vacuum hose to port "Q" of EGR vacuum modulator

(c) Connect the VSV connector.

32. INSTALL FUEL PRESSURE VSV, VCV AND VACUUM PIPE (AS EQUIPPED)

(a) Install the VSV with the bolt.
(b) Install the VCV and vacuum pipe with the bolt.
(c) Connect the two vacuum hoses to the vacuum pipe.
(d) Connect the VSV connector.
(e) Connect the pipe to the charcoal canister hose.
(f) Connect the hose to the BVSV.

33. INSTALL EGR PIPE
- Install two new gaskets and the EGR pipe with the three bolts and two new nuts.

Torque: 185 kg-cm (13 ft-lb, 18 N.m)

NOTE: Do not touch the EGR pipe. air intake chamber and exhaust manifold surfaces of the gaskets with your hand.

34. INSTALL TIMING BELT REAR PLATES

- Install the rear plate with the two bolts. Install the two rear plates.

Torque: 80 kg-cm (69 in-lb, 7.8 N.m)

35. INSTALL WATER INLET AND INLET HOUSING

Torque: 185 kg-cm (13 ft-lb, 18 N.m)

36. INSTALL RH IGNITION COIL
- Install the ignition coil with the two bolts.

37. INSTALL LOWER HIGH-TENSION CORD COVER

- Install the cord cover with the bolt.

38. INSTALL HIGH-TENSION CORD CLAMPS

- Install the clamp with the bolt. Install the four clamps.

39. CONNECT CABLES, AND ADJUST IT

(a) Accelerator cable
(b) A/T throttle cable
(c) Cruise control actuator cable

40. INSTALL CAMSHAFT TIMING PULLEY
41. FILL WITH ENGINE COOLANT
42. CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY
43. START ENGINE AND CHECK FOR LEAKS
44. CHECK ENGINE OIL LEVEL
45. CHECK IGNITION TIMING
- Ignition timing: 8 - 12° BTDC @ idle
(W/ Terminals TE1 and E1 connected)

46. PERFORM ROAD TEST
- Check for abnormal noise, shock, slippage, correct shift points and smooth operation.