Reassembly

CYLINDER HEAD

COMPONENTS:

REASSEMBLY

1. INSTALL RING W/HEAD PIN
a. Using a plastic-faced hammer, tap in a new ring pin to the specified protrusion height.
Protrusion height: 5.5 mm (0.22 inch)

2. INSTALL STUD BOLT
a. Install the stud bolt.
Torque:
Bolt A 5.0 Nm (51 kgf-cm, 44 inch lbs.)
Bolt B 5.0 Nm (51 kgf-cm, 44 inch lbs.)
Bolt C 10 Nm (102 kgf-cm, 7 ft. lbs.)
Bolt D 10 Nm (102 kgf-cm, 7 ft. lbs.)
3. INSTALL VALVE SPRING SEAT

4. INSTALL VALVE STEM OIL 0 SEAL OR RING
a. Apply a light coat of engine oil on a new oil seal.

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 gray and the exhaust valve oil seal is black.

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

5. INSTALL INTAKE VALVE
a. Install the valve, spring and retainer to the cylinder head.
b. Using SST and wooden blocks, compress the spring and install the 2 retainer locks.
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 valve stem tip.

6. INSTALL EXHAUST VALVE
a. Install the valve, spring and retainer to the cylinder head.
b. Using SST and wooden blocks, compress the spring and install the 2 retainer locks.
SST 09202-70020 (09202-00010)

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

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

7. INSTALL VALVE LIFTER
a. Assemble the valve lifter and the tip of the valve stem with a light coat of engine oil applied.

NOTICE: Install the valve lifters in their original places.

INSTALLATION

1. INSTALL CYLINDER HEAD GASKET
a. Place a new gasket on the cylinder block surface with the Lot No. stamp upward.

NOTICE:
^ Remove any oil from 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 SUB-ASSEMBLY

HINT: The cylinder head bolts are tightened in 2 progressive steps.

a. Apply a light coat of engine oil to the bolt threads and the area beneath the bolt heads that come in contact with the washers.
b. Install the bolts and plate washers to the cylinder head.

NOTICE: Do not drop the washers into the cylinder head.

c. Using a 10 mm bi-hexagon wrench, uniformly tighten the 10 bolts in the sequence shown in the illustration.
Torque: 79 Nm (806 kgf-cm, 58 ft. lbs.)

d. Mark the front side of the cylinder head bolt with paint.
e. Retighten the cylinder head bolts 90° in the sequence shown in the illustration.
f. Check that the painted mark is now at a 90° angle to the front.
3. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
4. INSTALL CAMSHAFT BEARING NO. 2
5. INSTALL CAMSHAFT
6. INSTALL NO. 2 CAMSHAFT
7. INSTALL CHAIN SUB-ASSEMBLY
8. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

9. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY
a. Install a new gasket and the exhaust manifold convert with the 5 nuts. Uniformly tighten the nuts in the sequence shown in the illustration.
Torque: 37 Nm (337 kgf-cm, 27 ft. lbs.)

b. Install the No. 1 and No. 2 exhaust manifold stays with the 2 bolts and 2 nuts.
Torque: 44 Nm (449 kgf-cm, 32 ft. lbs.)
10. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 1
Torque: 12 Nm (122 kgf-cm, 9 ft. lbs.)
11. INSTALL INTAKE MANIFOLD INSULATOR NO. 1
12. INSTALL ENGINE WIRE
13. INSTALL INTAKE MANIFOLD
14. INSTALL ENGINE MOUNTING BRACKET RR (for 4WD)

15. INSTALL ENGINE MOUNTING INSULATOR ASSEMBLY RR (for 4WD)
a. Install the mounting insulator with bolts.
Torque: 75 Nm (765 kgf-cm, 55 ft. lbs.)
16. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (for 4WD)
17. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
18. CONNECT FUEL TUBE SUB-ASSEMBLY
19. INSTALL FRONT SUSPENSION BRACE SUB-ASSEMBLY UPPER CENTER
Torque: 80 Nm (816 kgf-cm, 59 ft. lbs.)
20. ADD ENGINE OIL
21. ADD COOLANT
22. ADD TRANSFER OIL (for 4WD)
a. Install a new gasket and the filler plug.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
23. CHECK FOR ENGINE OIL LEAKS
24. CHECK FOR ENGINE COOLANT LEAKS
25. INSPECT FOR FUEL LEAKS
a. Inspect for the fuel leaks.
26. CHECK IDLE SPEED AND IGNITION TIMING
a. Check the idle speed and ignition timing.
27. INSPECT CO/HC
28. CHECK ABS SPEED SENSOR SIGNAL
29. INSPECT FRONT WHEEL ALIGNMENT