Installation
INSTALLATION
1. Place cylinder head on cylinder block.
a. Place a new cylinder head gasket in position on the cylinder block.
NOTICE: Be sure to install it correctly.
b. Place the cylinder head in position on the cylinder head gasket.
2. Install cylinder head bolts.
HINT:
- The cylinder head bolts are tightened in 3 progressive steps.
- If any of bolts break or deform, replace them.
a. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
b. Install the 14 plate washers to each cylinder head bolt.
c. Using a 10 mm bi-hexagon wrench, uniformly tighten the cylinder head bolts, in several passes, in the sequence shown.
Torque: 35 Nm (26 ft. lbs.)
If any of the bolts do 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. Retighten cylinder head bolts by an additional 90° shown.
g. Check that the painted mark is now turned to the rear.
3. Install camshafts.
a. Apply engine oil to the thrust portion of the camshaft.
b. Place the camshaft on the cylinder head with the cam lobe facing up as shown.
c. Place the (Nos. 3, 7 journal) camshaft bearing caps in their proper location.
d. Apply a light coat of engine oil on the threads and undo the heads of the bearing cap bolts.
e. Temporarily tighten these bearing cap bolts uniformly and alternately, in several passes, until the bearing caps are snug with the cylinder head.
f. Apply MP grease to a new camshaft oil seal lip.
g. Install the 2 oil seals to the camshafts.
h. Clean the installed surfaces of the Nos.1, 3 camshaft bearing cap and cylinder head with cleaner.
i. Apply seal packing to the bearing caps as shown.
Seal packing: Part No. 0882 - 00080 or equivalent
j. Install the other bearing caps in their proper locations.
k. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
l. Install and uniformly tighten the 14 bearing cap bolts on one side, in several passes, in the sequence shown.
Torque: 20 Nm (15 ft. lbs.)
m. Using a 5 mm hexagon wrench, the 2 No.3 camshaft bearing cap bolts.
Torque: 5.0 Nm (44 inch lbs.)
n. Using Special Service Tool (SST), push the 2 oil seals in as far as they can go.
SST 09316 - 60011 (09316 - 0011, 09316 - 0051)
o. Rotate the camshaft with a wrench at the hexagon position, bring the forward straight pin up.
p. Loosen the 12 bearing cap bolts as shown, until they can be turned by hand; retighten in several passes.
Torque: 20 Nm (15 ft. lbs.)
q. Turn the camshaft 1/3 of a revolution.
r. Loosen the 8 bearing cap bolts as shown, until they can be turned by hand; retighten in several passes.
Torque: 20 Nm (15 ft. lbs.)
s. Turn the camshaft a further 1/3 of a revolution.
t. Loosen the 8 bearing cap bolts as shown, until they can be turned by hand; retighten in several passes.
Torque: 20 Nm (15 ft. lbs.)
4. Check and adjust valve clearance.
5. Install No.4 timing belt cover.
Install the timing belt cover with 4 bolts.
Torque: 8.0 Nm m (71 inch lbs.)
6. Install camshaft timing pulleys.
a. Install the exhaust camshaft timing pulley.
1) Align the camshaft knock pin with the groove in the pulley, and slide on the pulley.
2) Slide the timing pulley on the camshaft, facing the front mark forward.
3) Hold the hexagon portion of the camshaft with a wrench, and tighten the timing pulley bolt.
Torque: 81 Nm (60 ft. lbs.)
b. Install the VVT-i (intake camshaft timing) pulley.
7. Connect timing belt to camshaft timing pulleys.
8. Install No.1 and No.2 cylinder head covers.
a. Remove the any old packing Formed In Place Gasket (FIPG), material.
b. Apply seal packing to the cylinder head as shown in the illustration.
Seal packing: Part No. 08826 00080 or equivalent
c. Install the gaskets to the cylinder head covers.
d. Install the cylinder head covers with the 12 bolts and 4 nuts.
Torque: 8.5 Nm (75 inch lbs.)
9. Install intake manifold assembly.
a. Install a new gasket and the intake manifold and delivery pipe assembly with the 7 bolts and 2 nuts.
Torque: 28 Nm (21 ft. lbs.)
b. Pass the water bypass hose between the No.2, No.3 intake ports of the manifold and delivery pipe.
c. Install the manifold stay with the 2 bolts.
Torque: 40 Nm (30 ft. lbs.)
d. Install the starter wire to the manifold stay.
10. Install fuel pressure pulsation damper.
11. Connect engine wire to cylinder head.
a. Install the engine wire protector with the 3 nuts.
b. Using a 5 mm hexagon wrench, install the bolt holding the engine wire protector to the No.2 cylinder head cover.
c. Connect these connectors:
- 6 injector connectors
HINT: The Nos.1, 3, 5 injector connectors and dark gray, and the Nos.2, 4, 6 injector connectors are brown.
- Camshaft timing oil control valve connector
- Camshaft position sensor connector
- ECT sensor connector
- 2 knock sensor connectors
- Starter connector
- Oil pressure switch connector
- Oil level sensor connector
d. Install the clamp bracket to the intake manifold.
e. Connect the 2 wire clamps to the No.1 oil pipe and clamp, bracket on the intake manifold.
f. Install the 2 ground terminals to the intake manifold.
Tighten so that each calking part should face inside.
g. Install the clamp bracket to the water pump.
h. Connect these connectors:
- Generator connector
- Crankshaft position sensor connector
- Heated oxygen sensor (bank 1 sensor 1) connector
i. Secure the engine wire with the clamp.
j. Install the 2 hose clamps to the cylinder head and oil filter bracket.
k. Install the heated oxygen sensor (bank 2 sensor 1 ) connector and engine wire clamp to the hose clamps.
l. Install the 2 water bypass hoses to the hose clamps on the cylinder head and oil filter bracket.
m. Install the ground strap to the cylinder head.
12. Install spark plugs.
13. Install ignition coils and high-tension cord set assembly.
14. Install No.3 timing belt cover.
Torque: 8.0 Nm (71 inch lbs.)
15. Install vacuum control valve set and No.2 vacuum pipe.
a. Install the vacuum control valve set and No.2 vacuum pipe with the 3 nuts.
Torque: 21 Nm (15 ft. lbs.)
b. Install the engine wire clamp to the clamp bracket of the No.2 vacuum pipe.
c. Connect the Vacuum Switching Valve (VSV), connector for the ACIS.
16. Install air intake chamber.
17. Install oil dipstick and guide for A/T.
18. Install oil dipstick and guide for engine.
19. Install throttle body and intake air connector assembly.
20. Install water bypass outlet and No.1 water bypass pipe.
21. Install exhaust manifold.
a. Install 2 new gaskets to the cylinder head.
b. Using a 14 mm deep socket wrench, install the exhaust manifold with the 8 nuts. Uniformly tighten the nuts in several passes.
Torque: 40 Nm (30 ft. lbs.)
c. Connect the 3 heated oxygen sensor connectors and clamp.
d. Install a new clamp and the case clamp as shown in the illustration.
22. Connect front exhaust pipe to exhaust manifold.
a. Temporarily install the pipe support bracket to the transmission with the 2 bolts.
b. Install 2 new gaskets to front end of the front exhaust pipe, and connect the front exhaust pipe to the exhaust manifold with the 3 bolts and nuts.
Torque: 44 Nm (32 ft. lbs.)
c. Tighten the 2 bolts holding the pipe support bracket to the transmission.
Torque: 44 Nm (32 ft. lbs.)
d. Connect the wire grommet and sensor wire of the the heated oxygen sensor (bank 2 sensor 2) to the hole and clamp on the floor.
23. Install PS pump.
a. Install the vane pump with the 2 bolts
Torque: 58 Nm (43 ft. lbs.)
b. Install the pump rear stay with the 2 bolts.
Torque: 39.2 Nm (29 ft. lbs.)
c. Connect these hoses:
- PS air hose to the No.4 timing belt cover
- PS air hose to the air intake chamber
24. Install drive belt.
25. Install air cleaner, map meter and intake air resonator assembly.
26. Install air cleaner inlet.
27. Connect upper radiator hose to water outlet
28. Fill with engine coolant
29. Start engine and check for leaks
30. Install engine under cover.
31. road test.
Check for abnormal noise, shock, slippage, correct shift points and smooth operation.
32. Re-Check engine coolant level.