Assembly

ASSEMBLY OF CYLINDER HEAD
HINT:
- Thoroughly clean all parts to be assembled.
- Before installing the parts, apply new engine oil to all sliding and rotating surfaces.
- Replace all gaskets and oil seals with new parts.






1. IN STALL VALVES
(a) Lubricate and insert valves in the cylinder head valve guides. Make sure the valves are installed in the correct order.
(h) Install the valve spring seats and new seals.






(e) Tap the stem lightly to assure proper fit.






2. INSTALL CAMSHAFT
(a) Place the camshaft in the cylinder head and install the bearing caps in numbered order from the front with arrows pointing toward the front.
(b) Install and torque the cap bolts.
Torque: 200 kg-cm (14 ft-lb, 20 N.m)
(c) Turn the camshaft to position the dowel at the top.






3. INSTALL CYLINDER HEAD REAR COVER
Install a new gasket, cylinder head rear cover and throttle cable clamp (for A/T) with the four bolts.
4. INSTALL LH ENGINE HANGER AND GROUND STRAP
5. INSTALL RH ENGINE HANGER






6. INSTALL PLUG PLATE
Install the new gaskets and plug plate with the two bolts.

HINT: Attach the flat side of the gasket to the cylinder head.

7. INSTALL INTAKE MANIFOLD
(a) Position a new gasket on the cylinder head.
(b) Install the intake manifold with the delivery pipe and injection nozzles and No.1 air pipe.
(c) Install the seven bolts, one hexagon bolt and two nuts. Torque the bolts and nuts.
Torque: 195 kg-cm (14 ft-lb, 19 N.m)
(d) Install the bolt the heater inlet pipe to the cylinder head.






(e) Install the read valve with the two nuts.






8. INSTALL EGR VALVE
(a) Clean the set bolt (closest to the front) threads and cylinder head bolt holes of any sealer, oil or foreign particles. Remove any oil with kerosene or gasoline.
(b) Apply sealant to 2 or 3 threads of the bolt end. Sealant: Part No.08833-00070, THREE BOND 1324 or equivalent
- This adhesive will not harden while exposed to air. It will act as a sealer or binding agent only when applied to threads, etc. and air is cut off.






(c) Install the EGR valve with the two bolts and nut.






9. INSTALL EXHAUST MANIFOLD
(a) Position a new gasket on the cylinder head.
(b) Install the exhaust manifold with eight nuts. Torque the nuts.
Torque: 450 kg-cm (33 ft-lb, 44 N.m)






INSTALLATION OF CYLINDER HEAD
1. APPLY SEAL PACKING TO CYLINDER BLOCK
(a) Apply seal packing to two locations as shown. Seal packing: Part No.08826-00080 or equivalent
(b) Place a new head gasket over dowels on the cylinder block.
2. INSTALL CYLINDER HEAD
(a) If the sprocket was removed, align the alignment marks placed on the sprocket and chain during removal.
(b) Position the cylinder head over dowels on the block.






3. INSTALL ROCKER ARM ASSEMBLY
(a) Place the rocker arm assembly over the dowels on the cylinder head.
(b) Install and tighten the head bolts gradually in three passes and in the sequence shown. Torque the bolts on the final pass.
Torque: 800 kg-cm (58 ft-lb, 78 N.m)