Installation

Various Engine Compartment Components:

Timing Belt Components:

Air Intake Chamber, Intake Manifold:

Exhaust System (Except California):

Exhaust System (California Only):

Cylinder Head And Related Components:

INSTALLATION





1. PLACE CYLINDER HEAD ON CYLINDER BLOCK
a. Place 2 new cylinder head gaskets in position on the cylinder block.

NOTICE: Be careful of the installation direction.

b. Place the 2 cylinder heads in position on the cylinder head gaskets.
2. INSTALL 12 POINTED HEAD CYLINDER HEAD BOLTS

HINT:
- The cylinder head bolts are tightened in 3 progressive steps (steps b, d and e).
- If any 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 cylinder head bolts on each cylinder head, in several passes, in the sequence shown, then repeat for the other side, as shown.
Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.)
If any of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt.





c. Mark the front of the cylinder head bolt 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.





3. INSTALL RECESSED HEAD CYLINDER HEAD BOLTS
a. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
b. Using an 8 mm hexagon wrench, install the cylinder head bolt on each cylinder head, then repeat for the other side, as shown.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)
4. CONNECT GROUND STRAP
Install the bolt and connect the ground strap.
5. ASSEMBLE EXHAUST CAMSHAFTS





a. Mount the hexagonal wrench head portion of the camshaft in a vise.

NOTICE: Be careful not to damage the camshaft.

b. Install the camshaft gear spring, camshaft sub - gear and wave washer.

HINT: Attach the pins on the gears to the gear spring ends.





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





d. Using SST, align the holes of the camshaft main gear and sub-gear by turning camshaft sub-gear clockwise, and temporarily install a service bolt.
SST 09960-10010 (09962-01000, 09963-00600)
e. Align the gear teeth of the main gear and sub-gear, and tighten the service bolt.

6. INSTALL CAMSHAFTS OF RH CYLINDER HEAD

NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be held level while it is being installed. If the camshaft is not 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.

a. Install the intake camshaft of the RH cylinder head.





1. Apply fresh engine oil to the thrust portion and journal of the camshaft.
2. Place the intake camshaft at 90° angle of timing mark (2 dot marks) on the cylinder head.





3. Apply MP grease to a new oil seal lip.
4. Install the oil seal to the camshaft.





5. Remove any old packing (FIPG) material.
6. Apply seal packing to the No.1 bearing cap as shown.
Seal packing: Part No. 08826-00080 or equivalent





7. Install the 5 bearing caps in their proper locations.





8. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
9. Install and uniformly tighten the 10 bearing cap bolts, in several passes, in the sequence shown.
Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.)
b. Install the exhaust camshaft of the RH cylinder head.





1. Apply fresh engine oil to the thrust portion and journal of the camshaft.
2. Align the timing marks (2 dot marks) of the camshaft drive and driven gears.
3. Place the exhaust camshaft on the cylinder head.





4. Install the 4 bearing caps in their proper locations.





5. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
6. Install and uniformly tighten the 8 bearing cap bolts, in several passes, in the sequence shown.
Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.)
7. Remove the service bolt.
c. Install the intake camshaft of the LH cylinder head.

NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be held level while it is being installed. If the camshaft is not 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.

d. Install the intake camshaft of the LH cylinder head.





1. Apply fresh engine oil to the thrust portion and journal of the camshaft.
2. Place the intake camshaft at 90° angle of timing mark (1 dot mark) on the cylinder head.





3. Apply MP grease to a new oil seal lip.
4. Install the oil seal to the camshaft.
5. Remove any old packing (FIPG) material.
6. Apply seal packing to the No.1 bearing cap.
Seal packing: Part No. 08826-00080 or equivalent





7. Install the 5 bearing caps in their proper locations.





8. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
9. Install and uniformly tighten the 10 bearing cap bolts, in several passes, in the sequence shown.
Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.)
e. Install the exhaust camshaft of the LH cylinder head.





1. Apply fresh engine oil to the thrust portion and journal of the camshaft.
2. Align the timing marks (1 dot mark) of the camshaft drive and driven gears.
3. Place the exhaust camshaft on the cylinder head.





4. Install the 4 bearing caps in their proper locations.





f. Apply a light coat of engine oil on the threads and under the heads of bearing cap bolts.
g. Install and uniformly tighten the 8 bearing cap bolts, in several passes, in the sequence shown.
Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.)
h. Remove the service bolt.
7. CHECK AND ADJUST VALVE CLEARANCE
8. INSTALL SEMI-CIRCULAR PLUGS
a. Remove any old packing (FIPG) material.





b. Apply seal packing to the semicircular plug grooves.
Seal packing: Part No. 08826-00080 or equivalent





c. Install the 4 semicircular plugs to the cylinder heads.





9. INSTALL CYLINDER HEAD COVERS
a. Apply seal packing to the cylinder heads as shown in the illustration.
Seal packing: Part No. 08820-00080 or equivalent
b. Install the gasket to the cylinder head cover.
c. Install the cylinder head cover with the 8 bolts. Uniformly tighten the bolts in several passes. Install the 2 cylinder head covers.
Torque: 6 Nm (60 kgf-cm, 53 inch lbs.)





10. INSTALL RH AND LH EXHAUST MANIFOLDS
Install 2 new gaskets and the RH and LH exhaust manifolds with the 12 nuts.
Torque: 40 Nm (400 kgf-cm, 30 ft. lbs.)





11. INSTALL EXHAUST CROSSOVER PIPE
Install 2 new gaskets and the crossover pipe with 6 new nuts.
Torque: 45 Nm (450 kgf-cm, 33 ft. lbs.)
12. INSTALL GENERATOR BRACKET
Torque: 18.5 Nm (185 kgf-cm, 13 ft. lbs.)
13. INSTALL OIL DIPSTICK AND GUIDE
a. Install a new O-ring to the dipstick guide.
b. Apply soapy water to the O-ring.
c. Push in the dipstick guide end into the guide hole of the oil pan.
d. Install the dipstick guide with the 2 bolts.
Torque: 8 Nm (80 kgf-cm, 71 inch lbs.)
e. Install the dipstick.
14. INSTALL PS PUMP BRACKET
Torque: 18.5 Nm (185 kgf-cm, 13 ft. lbs.)





15. INSTALL INTAKE MANIFOLD ASSEMBLY
a. Install 2 new gaskets and the intake manifold, the delivery pipe and injectors assembly with the 8 bolts, 4 plate washers and 4 nuts.
Torque: 18 Nm (180 kgf-cm, 13 ft. lbs.)
b. Install the intake manifold stay with the 2 bolts.
Torque: 18.5 Nm (185 kgf-cm, 13 ft. lbs.)
c. Connect the fuel inlet hose.
16. INSTALL FUEL PRESSURE REGULATOR





17. INSTALL NO.3 TIMING BELT COVER
a. Check that the timing belt cover gaskets have no cracks or peeling, etc.
If the gaskets do have cracks or peeling etc., replace them using these steps:
1. Using a screwdriver and gasket scraper, remove all the old gasket materials.
2. Thoroughly clean all components to remove all the loose material.
3. Remove the backing paper from a new gasket and install the gasket evenly to the part of the timing belt cover shaded black in the illustration.
b. Install the timing belt cover with the 6 bolts.
Torque: 9 Nm (90 kgf-cm, 80 inch lbs.)





18. INSTALL CAMSHAFT POSITION SENSOR
a. Install the camshaft position sensor with the bolt.
Torque: 8 Nm (80 kgf-cm, 71 inch lbs.)

HINT: Match the protrusion of the sensor with the indentation of the RH cylinder head.

b. Connect the clamp to the No.3 timing belt cover.
c. Connect the camshaft position sensor connector.
19. INSTALL TIMING BELT





20. CONNECT ENGINE WIRE
a. Install the engine wire with the 3 bolts.
b. Connect the 3 engine wire clamps.
c. Connect the oil pressure sensor connector.
d. Connect the crankshaft position sensor connector.
e. Connect the 6 injector connectors.
f. Connect the ECT sender gauge connector.
g. Connect the ECT sensor connector.
h. Connect the knock sensor connector.
i. Connect the camshaft position sensor connector.
21. INSTALL INTAKE AIR CONNECTOR





a. Install a new gasket and the intake air connector with the 3 bolts and 2 nuts.
Torque: 18.5 Nm (185 kgf-cm, 13 ft. lbs.)





b. Connect the DLC1 to the bracket.
c. Install the bolt holding the ground strap to the intake air connector.
d. Connect the brake booster vacuum hose to the intake air connector.
e. Connect the 2 fuel return hoses.
f. Connect the vacuum sensing hose.
g. Install the bolt holding the engine wire to the intake air connector.
22. INSTALL AIR INTAKE CHAMBER ASSEMBLY





a. Install a new gasket and the air intake chamber assembly with the 4 bolts and 2 nuts.
Torque: 18 Nm (180 kgf-cm, 13 ft. lbs.)





b. Connect the 2 PCV hoses.
c. Connect the 2 water bypass hoses.
d. Connect the air assist hose to the throttle body.
e. Connect the EVAP hose.
f. Connect the throttle position sensor connector.
g. Connect the IAC valve connector.
23. INSTALL AIR INTAKE CHAMBER STAY
a. Install the air intake chamber stay with the 2 bolts.
Torque:
14 mm head: 40 Nm (400 kgf-cm, 30 ft. lbs.)
12 mm head: 18.5 Nm (185 kgf-cm, 13 ft. lbs.)
b. A/T: Install a new O-ring to the oil filler tube.
c. Apply soapy water to the O-ring.
d. Push in the oil filler tube end into the tube hole of the oil pan.
e. Install the oil filler tube and No.1 throttle cable clamp with the 2 nuts and bolt.
f. Install the dipstick.
24. INSTALL GENERATOR
25. INSTALL NO.2 IDLER PULLEY
26. CONNECT HEATER HOSE AND UPPER RADIATOR HOSE
27. CONNECT CABLES
a. A/T: Connect the throttle cable.
b. Connect the accelerator cable.
c. w/ Cruise control: Connect the cruise control actuator cable.
28. INSTALL SPARK PLUGS
29. INSTALL HIGH-TENSION CORDS WITH IGNITION COILS
30. INSTALL MAP METER, RESONATOR AND AIR CLEANER CAP ASSEMBLY
31. INSTALL FRONT EXHAUST PIPE
32. FILL WITH ENGINE COOLANT
33. START ENGINE AND CHECK FOR LEAKS
34. INSTALL ENGINE UNDER COVER
35. ROAD TEST VEHICLE
Check for abnormal noise, shock, slippage, correct shift points and smooth operation.
36. RECHECK ENGINE COOLANT LEVEL