Installation

CYLINDER HEAD ASSEMBLY:

Installation






1. Set No. 1 piston at TDC on its compression stroke.






2. Before installing cylinder head gasket, apply a continuous bead of liquid gasket to mating surface of cylinder block.
3. Install cylinder head completely with intake and exhaust manifolds.
Apply engine oil to threads and seating surfaces of cylinder head bolts before installing them.






Be sure to install washers between bolts and cylinder head.






CAUTION: Cylinder head bolts are tightened by plastic zone tightening method. Whenever the size difference between d1 and d2 exceeds the limit, replace them with new ones.

Limit (d1 - d2):............0.15 mm (0.0059 inch)

If reduction of outer diameter appears in a position other than d2, use it as d2 point.

CYLINDER HEAD BOLTS - TORQUE SEQUENCE:

a. Tighten all bolts to 39.2 Nm (4.0 kg-m, 29 ft. lbs.).
b. Tighten all bolts to 78.5 Nm (8.0 kg-m, 58 ft. lbs.).
c. Loosen all bolts completely.
d. Tighten all bolts to 39.2 Nm (4.0 kg-m, 29 ft. lbs.).






e. Method A:
Turn all bolts 90 to 95 degrees clockwise with Tool or suitable angle wrench.






Method B:
If angle wrench is not available, do the following. Mark the side of all bolts with paint marks facing the front of the engine. Then turn them 90 to 95 degrees clockwise.

f. Turn all bolts 90 to 95 degrees clockwise.
g. Ensure that paint mark on each bolt faces the rear of the engine. (Method B only)
Do not turn any bolt 180 to 190 degrees clockwise all at once.






4. Install cylinder head outside bolts.
5. Install the following water hoses.
- Water hose for cylinder block.
- Water hoses for heater.






6. Install knock sensor harness connector.






7. Install starter motor.






8. Remove all traces of liquid gasket from mating surface of LH camshaft end bracket.
Also remove traces of liquid gasket from mating surface of cylinder head.

9. Apply liquid gasket to mating surface of LH camshaft end bracket as shown in illustration.
Use Genuine Liquid Gasket or equivalent.






10. Install camshafts and camshaft brackets. Position camshaft.
Exhaust camshaft key at about 12 o'clock
Intake camshaft key at about 10 o'clock
Apply engine oil to bearings and cam surfaces of camshafts before installing them.






Position camshaft brackets as shown in illustration.
Apply engine oil to threads and seating surfaces of camshaft bracket bolts before installing them.

Tightening Procedure

Camshaft Torque Sequence:

STEP 1:
Intake camshaft
Tighten bolts 9 - 10 in that order then tighten bolts 1 - 8 in numerical order.
2 Nm (0.2 kg-m, 1.4 ft. lbs.)

Exhaust camshaft
Tighten bolts 11 - 12 in that order then tighten bolts 1 - 10 in numerical order.
2 Nm (0.2 kg-m, 1.4 ft. lbs.)

STEP 2:
Tighten bolts in the specified order.
6 Nm (0.6 kg-m, 4.3 ft. lbs.)






STEP 3:
Tighten bolts in the specified order.
Bolt type A B
10 - 12 Nm (1.0 - 1.2 kg-m, 7.2 - 8.7 ft. lbs.)

Bolt type C
18 - 25 Nm (1.8 - 2.6 kg-m, 13 - 19 ft. lbs.)






11. Install camshaft sprockets. Line up mating marks on timing chain with mating marks on camshaft sprockets.






Lock camshafts as shown in figure and tighten to specified torque.

Camshafts:...........137 - 157 Nm (14.0 - 16.0 kg-m, 101 - 116 ft. lbs.)

Apply engine oil to threads and seating surfaces of camshaft sprocket bolts before installing them.






12. Install timing chain guide.
13. Install distributor.






Make sure that position of camshaft is as shown in figure.






Make sure that No. 1 piston is set at TDC and that distributor is set at No. 1 cylinder spark position.

14. Install chain tensioner.






Make sure the camshaft sprockets are tightened completely. Press cam stopper down and "press-in" sleeve until hook can be engaged on pin. When tensioner is bolted in position the hook will release automatically.






Make sure arrow "A" points toward engine front.






15. Install oil filter bracket (SR20DE engine only) and power steering oil pump bracket.
16. Install intake manifold supports.
17. Remove all old liquid gasket from mating surfaces of rocker cover and cylinder head.









18. Apply a continuous bead of liquid gasket to mating surfaces of rocker cover gasket and cylinder head.
Use Genuine Liquid Gasket or equivalent.

Rocker Cover Bolt Sequence:

19. Install rocker cover.

(1) Tighten bolts 1 - 10 - 11 - 13 - 8 in that order to 8 to 10 Nm (0.8 to 1.0 kg-m, 69 to 89 inch lbs.).
(2) Tighten bolts 1 through 13 in numerical order to 8 to 10 Nm (0.8 to 1.0 kg-m, 70 to 89 inch lbs.).


20. Refit spark plugs and leads.
21. Install vacuum hoses, fuel hoses, wires, harness, connectors and so on.
22. Install power steering oil pump and alternator.
23. Install water pump pulley and drive belts.
24. Install intake manifold collector and brackets.
25. Refit air duct to intake manifold.
26. Install radiator.
27. Refit hoses and refill with coolant.
28. Install engine side cover and front RH wheel.
29. Install engine under covers.