Steps 1-40

Installation





1. Install the exhaust manifold gasket.





2. Position the exhaust manifold.





3. Install the exhaust manifold nuts in the sequence shown.
4. Install the exhaust manifold heat shield.





1 Position the exhaust manifold heat shield.
2 Install the bolts.

5. Install the engine lifting eye hook bracket.





1 Position the engine lifting eye hook bracket.
2 Install the bolts.





6. Install a new cylinder head gasket.





7. Position the cylinder head.

8. CAUTION: The cylinder head bolts located in positions 4, 7, 9, and 12 are 127 mm (5.08 inch) in length and all others are 106 mm (4.24 in) in length.

CAUTION: The cylinder head bolt washers must be installed with the chamfered edge facing away from the cylinder head surface.

CAUTION: It is necessary to apply clean engine oil to the threads and seating surfaces of the cylinder head bolts before installing.





Install the cylinder head bolts in two stages in the sequence shown.
^ Stage 1: Tighten the bolts to 29 Nm (21 ft. lbs.).
^ Stage 2: Tighten the bolts to 59 Nm (44 ft. lbs.).





9. Loosen the cylinder head bolts completely in the sequence shown.





10. Tighten the cylinder head bolts in the indicated sequence.
11. Install the coolant crossover tube and lower radiator hose.





1 Position the coolant crossover tube and lower radiator hose.
2 Install the bolts.





12. Install the lower intake manifold gaskets.





13. Position the lower intake manifold.





14. Install the lower intake manifold bolts and nuts in three stages in the sequence shown.
^ Stage 1: Tighten all bolts and nuts to 4 Nm (35 inch lbs.).
^ Stage 2: Tighten all bolts and nuts to 18 Nm (13 ft. lbs.).
^ Stage 3: Tighten all bolts and nuts to 18 Nm (13 ft. lbs.).





15. Loosen the lower intake manifold bolts and nuts completely in the sequence shown.





16. Tighten the cylinder head bolts in two stages in the sequence shown.
^ Stage 1: Tighten the bolts to 29 Nm (21 ft. lbs.).
^ Stage 2: Tighten the bolts to 59 Nm (44 ft. lbs.).





17. Install the last cylinder head bolt.





18. Tighten the lower intake manifold bolts and nuts in three stages in the sequence shown.
^ Stage 1: Tighten all bolts and nuts to 4 Nm (35 inch lbs.).
^ Stage 2: Tighten all bolts and nuts to 9 Nm (80 inch lbs.).
^ Stage 3: Tighten all bolts and nuts to 9 Nm (80 inch lbs.).

19. Inspect the tappets.
20. Install the rocker arm shaft support.





1 Position the rocker arm shaft support.
2 Remove the rubber bands.

21. CAUTION: Set camshaft lobes so that valves are not lifted. Tightening the rocker arm shaft bolts with the valves lifted can result in damaged valve components.

CAUTION: The rocker arm shaft bolts must be tightened using a two-step method.

Install the rocker arm shafts and rocker arms.





1 Position the rocker arm shafts and rocker arms.
2 Install the 12 bolts using a two-step method to tighten.





22. Install the valve cover gasket.
23. Install the valve cover.





1 Position the valve cover.
2 Install the screws.

24. Install the upper intake manifold stabilizer bracket.





1 Position the upper intake manifold stabilizer bracket.
2 Install the bolt.





25. Connect the vacuum hoses to the valve cover.
26. Position the wire harness back.





1 Position the wire harness back.
2 Clip the wire clips to valve cover.

27. Connect the electrical connectors and the vacuum hose.





1 Connect the electrical connectors.
2 Connect the vacuum hose.

28. Connect the heater core hose to the coolant crossover tube.





1 Connect the heater core hose to the coolant crossover tube.
2 Position the clamp.

29. Install the RH exhaust manifold to engine lifting eye bracket.





1 Position the RH exhaust manifold to engine lifting eye bracket.
2 Install the bolts.

30. Install the seal plate.





1 Position the seal plate.
2 Install the four bolts.

31. Using the special tool, install the RH camshaft sprocket.





1 Position the RH camshaft sprocket.
2 Position the special tool.
3 Install the bolt.

32. Using the special tool, install the LH camshaft sprocket.





1 Position the LH camshaft sprocket.
2 Position the special tool.
3 Install the bolt.

33. CAUTION: Make sure the arrow on the timing belt is pointing away from the engine when installed.

CAUTION: A new timing belt has three white timing marks that indicate the correct timing positions of the camshafts and the crankshaft. These marks will help make sure that the engine is timed correctly. When the engine is correctly timed each white timing mark on the timing belt will be aligned with the corresponding camshaft and crankshaft timing mark on the crankshaft sprocket and the camshaft sprockets. There should be 40 timing belt teeth between the timing marks on the LH and RH camshaft sprockets and 43 teeth between the timing mark on the LH camshaft sprocket and the timing mark on the crankshaft sprocket.

CAUTION: It is necessary to verify that the camshaft timing marks are aligned with the timing marks on the seal plate, and that the crankshaft sprocket timing mark is aligned with the timing mark on the oil pump. When installing the timing belt, start at the crankshaft sprocket moving around to the camshaft sprockets in a counterclockwise direction.. Do not allow any slack in the timing belt between the crankshaft sprocket and camshaft sprockets. After all of the timing marks are matched up with the timing belt installed, slip the timing belt onto the timing belt tensioner.





Align the timing marks and install the timing belt
34. Raise the vehicle.





35. Install the crankshaft pulley bolt.





36. Rotate the tensioner clockwise and counterclockwise a minimum of two times.





37. Tighten the tensioner lock nut.





38. Turn the crankshaft clockwise a minimum of two times and slowly set piston number one at TDC.

39. CAUTION: Timing belt deflection specification is for a cold engine.

Measure the timing belt deflection between the camshaft sprockets.





1 Apply pressure midway between the camshaft sprockets.
2 Measure the timing belt deflection.





40. Remove the crankshaft pulley bolt.