Cylinder Head Installation

1. Place cylinder head on cylinder block.





(a) Apply seal packing to the 2 locations as shown.
Seal packing: Part No. 08826 - 00080 or equivalent.

CAUTION: Do not apply too much seal packing.





(b) Place a new cylinder head gasket in position on the cylinder block.

CAUTION: Be careful of the installation direction.

(c) Place the cylinder head in position on the cylinder head gasket.
2. Install cylinder head bolts.

NOTE:
- The cylinder head bolts are tightened in progressive steps (steps (b) through (e)).
- If any cylinder head bolt is broken or deformed, replace it.

(a) Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.





(b) Install and uniformly tighten the 10 cylinder head bolts and plate washers, in several passes, in the sequence shown.
Torque: 39 Nm (29 ft. lbs.)
If any of the cylinder head bolts do not meet the torque specification, replace the cylinder head bolt.
(c) Mark the front of the cylinder head bolt head with paint.





(d) Retighten the cylinder head bolts by 90° in the numerical order shown.
(e) Retighten the cylinder head bolts by an additional 90°.
(f) Check that the painted mark is now facing rearward.





(g) Install and torque the 2 bolts.
Torque: 21 Nm (15 ft. lbs.)
3. Assemble exhaust camshaft.
(a) Mount the hexagon wrench head portion of the camshaft in a vise.

CAUTION: Be careful not to damage the camshaft.





(b) Install these parts:
(1) Camshaft gear spring.
(2) Camshaft sub-gear.
(3) Wave washer.

NOTE: Align the pins on the gears with the spring ends.

(c) Using snap ring pliers, install the snap ring.





(d) Using Special Service Tool (SST) Variable Pin Wrench Set # 09960-10010 (Variable Pin Wrench Arm Assy. # 09962-01000, Pin 5 # 09963-00500) or equivalents, align the holes of the camshaft main gear and sub-gear by turning sub-gear clockwise, and install a service bolt.
4. Install camshafts.

CAUTION: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, these steps should be carried out.

- Install intake camshaft.
(a) Apply Multipurpose (MP) grease to the thrust portion of the intake camshaft.





(b) Place the intake camshaft with knock pin facing upward of camshaft angle on the cylinder head.





(c) Install the bearing caps in their proper locations.
(d) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.





(e) Install and uniformly tighten the 10 bearing cap bolts in the sequence shown.
Torque: 15.5 Nm (12 ft. lbs.)
- Install exhaust camshaft.
(a) Apply MP grease to the thrust portion of the exhaust camshaft.





(b) Engage the exhaust camshaft gear to the intake cams shaft gear by matching the timing marks (1 and 2 dots) on each gear.

CAUTION: There are also timing marks (for TDC) on each gear as shown in the illustration. Do not use these marks.

(c) Roll down the exhaust camshaft onto the bearing journals while engaging gears with each other.





(d) Install the bearing caps in their proper locations.
(e) Apply light coat of engine oil on the threads and under the heads of the bearing cap bolts.





(f) Install and uniformly tighten the 10 bearing cap bolts, in several passes, in the sequence shown.
Torque: 15.5 Nm (12 ft. lbs.)
(g) Remove the service bolt.
(h) Check that the intake and exhaust camshafts turn smoothly.
5. Set No. 1 cylinder to TDC/compression.
(a) Turn the crankshaft pulley clockwise, and align its groove with the timing mark "0" of the timing chain cover.





(b) Turn the camshafts so that the timing marks with 1 and 2 dots will be in straight line on the cylinder head surface as shown in the illustration.
6. Install camshaft timing gear.





NOTE: Check that the matchmarks on the camshaft timing gear and timing chain are aligned.

(a) Place the gear over the straight pin of the intake camshaft.
(b) Hold the intake camshaft with a wrench, install and torque the bolt.
Torque: 73.5 Nm (54 ft. lbs.)
7. Install chain tensioner.





(a) Place a new gasket so that the front mark is toward the front side.





(b) Release the ratchet pawl, fully push in the plunger and apply the hook to the pin so that the plunger cannot spring out.
(c) Turn the crankshaft pulley clockwise to provide some slack for the chain on the tensioner side.

CAUTION: Do not turn the pulley counterclockwise.





(d) Push the tensioner by hand until it touches the head installation surface, then install the 2 nuts.
(e) Tighten the 2 nuts.
Torque: 21 Nm (15 ft. lbs.)
(f) Check that the hook of the tensioner is not released.

CAUTION: If the plunger springs out during installation of the chain tensioner, repeat the operation in step (b) before installing the tensioner.

8. Set chain tensioner.





Turn the crankshaft to the left so that the hook of the chain tensioner is released from the pin of the plunger, causing the plunger to spring out and the slipper to be pushed in to the chain.





NOTE: If the plunger does not spring out, press the slipper into the chain tensioner with a screwdriver or your finger so that the hook is released and the plunger springs out.

9. Check valve timing.
(a) Turn the crankshaft pulley, and align its groove with the timing mark "0" of the timing chain cover.

CAUTION: Always turn the crankshaft clockwise.





(b) Check that the timing marks (1 and 2 dots) of the camshaft drive and driven gears are in straight line on the cylinder head surface as shown in the illustration.
If not, turn the crankshaft 1 revolution (360°) and align the marks as above.
10. Check and adjust valve clearance.
Valve clearance (Cold):
Intake: 0.15 - 0.25 mm (0.006 - 0.010 inch)
Exhaust: 0.25 - 0.35 mm (0.010 - 0.014 inch)
11. Install spark plugs.
12. Install semi-circular plugs.
(a) Remove any old packing Formed In Place Gasket (FIPG) material.





(b) Apply seal packing to the cylinder head installation surface of the semi-circular plugs.
Seal packing: Part No. 08826 - 00080 or equivalent.
(c) Install the semi-circular plug to the cylinder head.
13. Install cylinder head cover.
14. Install engine wire brackets.
15. Install front engine hanger.
Torque: 42 Nm (30 ft. lbs.)
16. Install cylinder head rear cover.
Install a new gasket and the rear cover with the 3 bolts.
Torque: 13.5 Nm (10 ft. lbs.)
17. Install water outlet.
(a) Install a new gasket and the water outlet with the 2 bolts.
Torque: 20 Nm (14 ft. lbs.)
(b) Connect the upper radiator hose.
18. Install exhaust manifold.
(a) Install a new gasket and the exhaust manifold with the 6 nuts.
Torque: 49 Nm (36 ft. lbs.)
(b) Install the heat insulator with the 2 bolts and 2 nuts.
Torque: 5.5 Nm (48 inch lbs.)
19. Install front exhaust pipe.
20. Install intake manifold.
Install a new gasket and the intake manifold with the 3 bolts and 2 nuts.
Torque: 29 Nm (22 ft. lbs.)
21. Install injectors and delivery pipe.

NOTE: When using a new cylinder head, spacers must be installed.





Apply a light coat of gasoline to a new O-ring install it to a new spacer.
22. Install fuel return pipe.
23. Install fuel inlet pipe.
Install the fuel inlet pipe and 4 new gaskets with 2 union bolts.
Torque: 29 Nm (22 ft. lbs)
24. Connect injector connectors.
25. Install air intake chamber assembly.
(a) Install a new gasket and the air intake chamber assembly with the 3 bolts and 2 nuts.
Torque: 21 Nm (15 ft. lbs.)
Connect these hoses:
- Evaporative Emission (EVAP) hose to throttle body.
- Brake booster vacuum hose to union.
- Water bypass hose to water bypass pipe.
- Water bypass hose to cylinder head rear cover.
26. Install intake chamber stay.
Torque: 20 Nm (15 ft. lbs.)





27. Install EGR pipe.
Install 2 new gaskets and EGR pipe with the bolt and 4 nuts.
Torque:
Bolt: 18 Nm (13 ft. lbs.)
Nut A: 19 Nm (14 ft. lbs.)
Nut B: 20 Nm (15 ft. lbs.)
28. Connect engine wire.
29. Install distributor.
30. Install PCV hoses.
31. Install Power Steering (PS) pump and bracket.
(a) Install the PS pump bracket with the 4 bolts.
Torque: 20 Nm (15 ft. lbs.)
(b) Connect the PS pump to the bracket with the 2 bolts.
Torque: 58 Nm (43 ft. lbs.)
(c) Connect the 2 air hoses to the throttle body and air intake chamber.





(d) Using SST Variable Pin Wrench Set # 09960 - 10010 (Variable Pin Wrench Arm Assy. # 09962 - 01000, Pin 10 # 09963 - 01000) or equivalents, install the PS pump pulley with the nut.
Torque: 43 Nm (32 ft. lbs.)
32. Install drive belt idler pulley for PS pump.
Torque: 20 Nm (14 ft. lbs.)
33. Install drive belt for PS pump.
34. Install oil dipstick guide.
Torque: 20 Nm (15 ft. lbs.)
35. Install intake air connector.
Torque: 18 Nm (13 ft. lbs.)
36. Install air cleaner cap, MAF meter and resonator assembly.





37. Connect these cables:
- M/T: Connect the throttle cable to the throttle body.
- A/T: Connect the accelerator and throttle cables to the throttle body.
- w/ Cruise Control System: Connect the cruise control cable to the actuator, and install the actuator cover.
38. Fill with engine coolant.
39. Start engine and check for leaks.
40. Vehicle road test.
Check for abnormal noise, shock, slippage, correct shift points and smooth operation.
41. Recheck engine coolant level.