Reassembly

CYLINDER HEAD

COMPONENTS:

REASSEMBLY

1. INSTALL RING W/HEAD PIN (for RH Side)
a. Using a plastic-faced hammer, tap in a new ring pin to the specified protrusion height.
Protrusion height: 3 mm (0.12 inch)

2. INSTALL RING PIN (for LH Side)
a. Using a plastic-faced hammer, tap in a new ring pin to the specified protrusion height.
Protrusion height: 3 mm (0.12 inch)

3. INSTALL SPARK PLUG TUBE
a. Using paint, mark the standard position from the edge.
Standard protrusion height: 42.4 to 43.4 mm (1.669 to 1.709 inch)

HINT: Use either end of the spark plug tube.

b. Apply adhesive to the spark plug tube where it will be pressed into the cylinder head.
Adhesive: Part No. 08833-00070 THREE BOND 1324 or equivalent

NOTICE:
^ Install the spark plug tube within 3 minutes after applying adhesive.
^ Do not deform the spark plug tube.
^ Do not expose the seal to coolant for at least 1 hour after installing.

c. Using a press and wooden block, install the spark plug tube to the required protrusion height.

NOTICE: Be careful not to drip the adhesive.

4. INSTALL PCV PIPE (for RH Side)
a. Using a wooden block and hammer, tap in 2 new PCV pipes until its top edge is flush with the cylinder head edge.

NOTICE: Be careful not to damage the cylinder head edge.

5. INSTALL STUD BOLT
a. Install the stud bolts on the intake side.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
6. INSTALL STUD BOLT
a. Install the stud bolts on the exhaust side.
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)

7. INSTALL VALVE STEM OIL 0 SEAL OR RING
a. Apply a light coat of engine oil on the valve stem.

NOTICE: Pay close attention when installing the intake and exhaust oil seals. For example, installing the intake oil seal into the exhaust or installing the exhaust oil seal to the intake can cause installation problems later.

HINT: The intake valve oil seal is light brown and the exhaust valve oil seal is gray.

b. Using SST, push in a new oil seal.
SST 09201-41020

NOTICE: Failure to use SST will cause the seal to be damaged or improperly seated.

8. INSTALL INTAKE VALVE
a. Install the valve, spring seat, valve spring and spring retainer.

NOTICE: Install the same part in the same combination to the original locations.

b. Using SST, compress the valve spring and place the 2 keepers around the valve stem.
SST 09202-70020 (09202-00010)

9. INSTALL EXHAUST VALVE
a. Install the valve, spring seat, valve spring and spring retainer.

NOTICE: Install the same parts in the same combination to the original locations.

b. Using SST, compress the valve spring and place the 2 keepers around the valve stem.
SST 09202-70020 (09202-00010)

c. Using a plastic-faced hammer and a discarded valve with its tip wrapped in tape, lightly tap the installed valve to ensure that it is securely fit.

NOTICE: Be careful not to damage the installed valve stem tip.

10. INSTALL VALVE LIFTER
a. Apply a light coat of engine oil to the valve lifter.

NOTICE: Install the same part in the same combination to the original locations.

b. Install the valve lifter.
c. Check that the valve lifter rotates smoothly by hand.

11. INSTALL SEMICIRCULAR PLUG
a. Remove any old seal packing (FIPG) material.
b. Apply seal packing to the semicircular plug grooves.
Seal packing: Part No. 08826-00080 or equivalent

c. Install the 2 semicircular plugs to the cylinder heads.

NOTICE:
^ Install the plugs so that they are flush with the top of the cylinder head.
^ Install the semicircular plugs within 3 minutes after applying seal packing.
^ Do not expose the seal to engine oil for at least 2 hours after installing.

12. INSTALL W/HEAD STRAIGHT SCREW PLUG NO. 1 (for RH Side)
a. Using a straight hexagon wrench 14, install 2 new gaskets and the 2 screw plugs.
Torque: 44 Nm (449 kgf-cm, 32 ft. lbs.)
13. INSTALL W/HEAD STRAIGHT SCREW PLUG NO. 2 (for LH Side)
a. Using a straight hexagon wrench 14, install 2 new gaskets and the 2 screw plugs.
Torque: 44 Nm (449 kgf-cm, 32 ft. lbs.)

INSTALLATION

1. INSTALL CYLINDER HEAD GASKET NO. 2
a. Place a new cylinder head gasket on the cylinder block with the L mark, as shown in the illustration.

NOTICE:
^ Remove any oil from the contact surface.
^ Be careful of the installation direction.
^ To avoid damage to the gasket, place the cylinder head on the gasket carefully.

2. INSTALL CYLINDER HEAD LH

NOTICE: The cylinder head bolts are tightened in 2 successive steps.

a. Apply a light coat of engine oil on the threads of the cylinder head bolts.
b. Install the plate washer to the cylinder head bolt.
c. Uniformly install and tighten the 8 cylinder head bolts in the sequence shown in the illustration (procedure "A").
Torque: 54 Nm (550 kgf-cm, 40 ft. lbs.)

d. Mark the front side of each cylinder head bolt head with paint, as shown in the illustration.
e. Retighten the cylinder head bolts by 90° in the same sequence as procedure "A".
f. Check that each painted mark is now at a 90° angle to the front.

g. Using a socket hexagon wrench 8, install the hexagon bolt.
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)
h. Install the wire harness clamp bracket with the bolt.
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)
i. Connect the ground cable with the bolt.
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)

3. INSTALL CYLINDER HEAD GASKET
a. Place a new cylinder head gasket on the cylinder block with the R mark upside down, as shown in the illustration.

NOTICE:
^ Remove any oil from the contact surface.
^ Be careful of the installation direction.
^ To avoid damage to the gasket, place the cylinder head on the gasket carefully.

4. INSTALL CYLINDER HEAD SUB-ASSEMBLY

NOTICE: The cylinder head bolts are tightened in 2 successive steps.

a. Apply a light coat of engine oil on the threads of the cylinder head bolts.
b. Install the plate washers to the cylinder head bolts.
c. Uniformly install and tighten the 8 cylinder head bolts in the sequence shown in the illustration (procedure "A").
Torque: 54 Nm (550 kgf-cm, 40 ft. lbs.)

g. Using a socket hexagon wrench 8, install the hexagon bolt.
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)
h. Connect the engine wire harness clamp with the nut.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
5. INSTALL NO. 4 CAMSHAFT SUB-ASSEMBLY
6. INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY
7. INSTALL NO. 2 CAMSHAFT
8. INSTALL CAMSHAFT
9. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
10. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
11. INSTALL IGNITION COIL ASSEMBLY
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
12. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY NO. 2
13. CONNECT EXHAUST PIPE ASSEMBLY FRONT
14. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY
15. CONNECT EXHAUST PIPE SUB-ASSEMBLY FRONT NO. 3
16. INSTALL PROPELLER SHAFT (for 4WD)
17. INSTALL VANE PUMP ASSEMBLY
18. INSTALL TIMING BELT NO. 3 COVER
19. INSTALL CAMSHAFT TIMING PULLEY
20. INSTALL TIMING BELT IDLER SUB-ASSEMBLY NO. 2
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.)
21. INSPECT TIMING BELT
22. INSTALL TIMING BELT
23. INSTALL TIMING BELT TENSIONER ASSEMBLY
24. INSTALL TIMING BELT GUIDE NO. 2
25. INSTALL ENGINE MOUNTING BRACKET RH
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)
26. INSTALL TIMING BELT NO. 2 COVER
27. INSTALL TIMING BELT NO. 1 COVER
28. INSTALL CRANKSHAFT PULLEY
29. INSTALL GENERATOR BRACKET NO. 2
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)
30. INSTALL ENGINE MOUNTING STAY NO. 2 RH
31. INSTALL ENGINE MOVING CONTROL ROD
32. INSTALL VANE PUMP V BELT
33. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO. 1
34. INSPECT DRIVE BELT TENSION
35. INSTALL OIL LEVEL GAGE GUIDE
36. INSTALL OIL LEVEL GAGE SUB-ASSEMBLY
37. INSTALL WATER INLET PIPE
38. CONNECT RADIATOR HOSE OUTLET
39. INSTALL WATER OUTLET
40. CONNECT RADIATOR HOSE INLET
41. INSTALL INTAKE MANIFOLD
42. CONNECT HEATER INLET WATER HOSE
43. CONNECT FUEL PIPE SUB-ASSEMBLY NO. 1
44. INSTALL INTAKE AIR SURGE TANK
45. INSTALL EMISSION CONTROL VALVE SET
46. INSTALL AIR CLEANER CASE
47. INSTALL AIR CLEANER FILTER ELEMENT SUBASSEMBLY
48. INSTALL AIR CLEANER CAP SUB-ASSEMBLY
49. CONNECT VACUUM HOSES
50. INSTALL V-BANK COVER SUB-ASSEMBLY
51. INSTALL FRONT SUSPENSION BRACE SUB ASSEMBLY UPPER CENTER
Torque: 80 Nm (816 kgf-cm, 59 ft. lbs.)
52. INSTALL COWL PANEL SUB-ASSEMBLY
53. INSTALL WINDSHIELD WIPER LINK ASSEMBLY
54. INSTALL COWL TOP VENTILATOR LOUVER SUBASSEMBLY
55. INSTALL FR WIPER ARM LH
56. INSTALL FR WIPER ARM RH
57. INSTALL FRONT WHEEL RH
58. ADD ENGINE OIL
59. ADD ENGINE COOLANT
60. CHECK FOR ENGINE OIL LEAKS
61. CHECK FOR ENGINE COOLANT LEAKS
62. INSPECT FOR FUEL LEAKS
63. CHECK FOR EXHAUST GAS LEAKS
64. INSPECT IGNITION TIMING
65. INSPECT ENGINE IDLE SPEED
66. INSPECT COMPRESSION
67. INSPECT CO/HC