Installation

1. Align crank sprocket alignment mark with the mark on the oil pump body as shown.
2. Confirm that the knock pin on the camshaft is set at the top.





3. Apply sealant to both drain plugs and install.





4. Install the washers between the bolts and cylinder head as shown.
5. Install new head gaskets.

Caution: Do not rotate the crank and cam separately or the valves will hit the piston and bend.





6. Torque head bolts in the order shown in the following manner:
1) Torque all bolts to 29 Nm (22 ft.lbs)
2) Torque all bolts to 59 Nm (43 ft.lbs)
3) Loosen all bolts completely
4) Torque all bolts to 29 Nm (22 ft.lbs)
5) Turn all bolts 60 to 65° clockwise. If an angle wrench is not available, torque all bolts to 54 - 64 Nm (40 - 47 ft.lbs).

Note: Bolts for spots 4, 5, 12 and 13 are longer than the others, do not mix these up.





7. Install exhaust front tube to exhaust manifold.








8. RH and LH cam sprockets are different, note positioning above and identification marks and install in the correct locations.
9. Install timing belt and adjust as necessary.





10. Install the intake manifold and torque the bolts in the order shown. Torque to 18 - 22 Nm (13 -16 ft.lbs).
11. Install fuel injectors and fuel rail.
12. Install fuel feed and return hoses, and engine side heater hose.
13. Install all vacuum hoses connected to the vacuum gallery and the fuel pressure regulator.
14. Install the vacuum gallery and, on California vehicles, the electrical connector for the exhaust gas temperature sensor.
15. Connect the EGR control solenoid valve, power valve control solenoid, engine temperature sensor and switch.
16. Connect all the electrical connectors for the fuel injectors.





17. Install the lower intake manifold collector and torque bolts as shown. Torque to 18 - 22 Nm (13 - 16 ft.lbs).
18. Install the EGR flare tube.
19. Install the vacuum hoses for the EGR control valve, brake master cylinder, swirl control valve and vacuum gallery.
20. Connect the PCV hoses and the water hose for the air cut valve.
21. Connect the electrical connectors for the idle switch, throttle sensor, and the A.A.C. valve.





22. Install the upper intake manifold collector and torque bolts in the order shown. Torque to 18 - 22 Nm (13 - 16 ft.lbs).





23. Align mark on distributor shaft with the protruding mark on the housing and install the distributor.





24. After installing, confirm that the distributor rotor head position matches the image above. Fill cooling system with coolant.
25. Install the valve covers, connect the negative battery cable and install the A.S.C.D. and accelerator control cables.





26. Remove the valve covers and, with the rocker arm in it's free position, check each hydraulic valve lifter by pushing the plunger forcefully with your finger.
27. If the lifter moves more than 1mm (0.04 in.), air may be inside. Bleed off the air by running the engine at 1,000 rpm under no load for about 10 minutes. If the lifters are still noisy, replace them and repeat from step 26.
28. Reinstall valve covers.