Installation

Cylinder Head Assembly:

Installation
1. Set No. 1 piston at TDC on its compression stroke as follows
a. Align crankshaft sprocket aligning mark with mark on oil pump body.
b. Confirm that knock pin on camshaft is set at the top.










2. Install both drain plugs.
Use Genuine Silicone RTV or equivalent.






3. Install exhaust manifolds to cylinder head.






4. Install cylinder head with new gasket.
Be sure to install washers between bolts and cylinder head.
Do not rotate crankshaft and camshaft separately, or valves will hit piston heads.

Cylinder Head Cover:

5. Tighten cylinder head bolts in numerical order using angle wrench [ST10120000 (324239-01)].
Apply engine oil to threads and seating surfaces of cylinder head bolts before installing them.

Cylinder head bolts for 4, 7, 9 and 12 are longer (L1) than the others.
L1:..............127 mm (5.00 inch) for 4, 7, 9 and 12
L2:..............106 mm (4.17 inch) for others







Install intake manifold and cylinder head at the same time using the following procedure:
1. Tighten cylinder head bolts to 29 Nm (3.0 kg-m, 22 ft. lbs.).
2. Tighten cylinder head bolts to 59 Nm (6.0 kg-m, 43 ft. lbs.).
3. Loosen cylinder head bolts completely.
4. Tighten cylinder head bolts to 10 Nm (1.0 kg-m, 7 ft. lbs.).
5. Tighten intake manifold bolts and nuts to 4 Nm (0.4 kg-m, 2.9 ft. lbs.).
6. Tighten intake manifold bolts and nuts to 18 Nm (1.8 kg-m,13 ft. lbs.).
7. Tighten intake manifold bolts and nuts to 16 to 20 Nm (1.6 to 2.0 kg-m, 12 to 14 ft. lbs.).
8. Loosen intake manifold bolts and nuts completely.
9. Tighten cylinder head bolts to 29 Nm (3.0 kg-m, 22 ft. lbs.).
10. Turn cylinder head bolts to 60 to 65 degrees clockwise.
If an angle wrench is not available, tighten cylinder head bolts to 54 to 64 Nm (5.5 to 6.5 kg-m, 40 to 47 ft. lbs.).
11. Tighten cylinder head sub-bolts to 9.0 to 11.8 Nm (0.92 to 1.20 kg-m, 6.7 to 8.7 ft. lbs.).
12. Tighten intake manifold bolts and nuts to 4 Nm (0.4 kg-m, 2.9 ft. lbs.).
13. Tighten intake manifold bolts and nuts to 9 Nm (0.9 kg-m, 6.5 ft. lbs.).
14. Tighten intake manifold bolts and nuts to 8 to 10 Nm (0.8 to 1.0 kg-m, 5.8 to 7 ft. lbs.).

Intake Manifold Installation Sequence:

If only intake manifold is removed and to be used again, install it using the following procedure:
1. Tighten all bolts and nuts to 4 Nm (0.4 kg-m, 2.9 ft. lbs.).
2. Tighten all bolts and nuts to 9 Nm (0.9 kg-m, 6.5 ft. lbs.).
3. Tighten all bolts and nuts to 8 to 10 Nm (0.8 to 1.0 kg-m, 5.8 to 7 ft. lbs.).


CAUTION: If replacing intake manifold with a new one, cylinder head gasket must also be replaced with a new one. Refer to step 4.

Rocker Arm Cover Assembly Sequence:

6. Install both rocker covers.






7. Install compressor, generator and power steering pump brackets.
8. Install power steering pump.
9. Install compressor and generator.
10. Install exhaust front tube to exhaust manifold.

Fig. 9 Camshaft Pulley Identification:

11. Install rear belt cover and camshaft sprocket.






RH camshaft sprocket and LH camshaft sprocket are different parts Be sure to install them in the correct location.

12. Install timing belt and adjust belt tension.
13. Install distributor.






1. Align mark on shaft with protruding mark on housing.






2. After installing, confirm that distributor rotor head is set as shown in figure.






14. Install injector fuel tube assembly.
15. Connect all injector harness connectors.
16. Install fuel feed and fuel return hoses to injector fuel tube assembly.
17. Install intake manifold collector. Install all parts which were removed in Step 6, under "Removal".
18. Install ASCD and accelerator control wire.






19. Check hydraulic valve lifter.
a. Push plunger forcefully with your finger.
Be sure to check it with rocker arm in its free position (not on the lobe).

b. If valve lifter moves more than 1 mm (0.04 inch), air may be inside it.
c. Bleed air off by running engine at 1,000 rpm under no load for about 10 minutes.
d. If hydraulic valve lifters are still noisy, replace them and bleed air off again in the same manner as in Step 19 (c).

20. Install the remaining components in the reverse order of removal.