Cylinder Head Installation

Components For Engine Removal (Part 1 Of 3):

Components For Engine Removal (Part 2 Of 3):

Components For Engine Removal (Part 3 Of 3):

1. Install cylinder head as follows:






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

NOTE: Be sure to install it correctly.

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

(c) Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
(d) Install the 14 plate washers to each cylinder head bolt.

NOTE:
^ The cylinder head bolts are tightened in 3 progressive steps.
^ If any of bolts break or deform, replace them.






(e) Using a 10 mm hi-hexagon wrench, uniformly tighten the cylinder head bolts, in several passes, in the sequence shown to 34 Nm (350 kg. cm., 25 ft. lbs.).

NOTE: If any of the bolts do not meet the torque specification, replace the bolt.






(f) Mark the front of the cylinder head bolt head with paint.






(g) Tighten the cylinder head bolts by 90° in the numerical order shown in the illustration.
(h) Tighten cylinder head bolts by an additional 90° shown in the illustration.
(i) Check that the painted mark is now turned to the rear.
2. Install camshafts as follows:
(a) Apply engine oil to the thrust portion of the camshaft.






(b) Place the camshaft on the cylinder head with the cam lobe facing up as shown.






(c) Place the No.3 and No.7 bearing caps in their proper location.
(d) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.






(e) Hand tighten these bearing cap bolts uniformly and alternately, in several passes, until the bearing caps are snug with the cylinder head.






(f) Apply Multipurpose (MP) grease to a new camshaft oil seal lip.






(g) Install the two oil seals to the camshafts.






(h) Clean the installed surfaces of the No.1 bearing cap and cylinder head with cleaner.
(i) Apply seal packing part No. 08826-00080, or equivalent, to the No.1 bearing cap as shown.






(j) Install the No.1, No.2, No.4, No.5 and No.6 bearing caps in their proper locations.
(k) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.






(l) Install and uniformly tighten the 14 bearing cap bolts on one side, in several passes, in the sequence shown, to 20 Nm (200 kg. cm, 14 ft. lbs.).






(m) Using seal driver Special Service Tool (SST) No. 09316-6OO11, or equivalent, push the two oil seals in as far as they can go.






(n) Rotate the camshaft with a wrench at the hexagon position, bring the forward straight pin up.
(o) Loosen the 12 bearing cap bolts as shown, until they can be turned by hand; retighten, in several passes to 20 Nm (200 kg. cm., 14 ft. lbs.).






(p) Turn the camshaft 1/3 of revolution.
(q) Loosen the eight bearing cap bolts as shown, until they can be turned by hand; retighten, in several passes to 20 Nm (200 kg. cm., 14 ft. lbs.).






(r) Turn the camshaft a further 1/3 of a revolution.
(s) Loosen the eight bearing cap bolts as shown, until they can be turned by hand; retighten, in several passes to 20 Nm (200 kg. cm., 14 ft. lbs.).
3. Check and adjust valve clearance, refer to Camshaft, Lifters and Push Rods / Adjustments.






4. Install the NO.4 timing belt cover with four bolts and tighten to: 7.8 Nm (80 kg. cm., 69 inch lbs.).
5. Install camshaft timing pulleys as follows:






(a) Align the camshaft knock pin with the groove in the pulley, and slide on the pulley.
(b) Hand tighten the timing pulley bolt.






(c) Hold the hexagon portion of the camshaft with a wrench, and tighten the timing pulley bolt to: 79 Nm (810 kg. cm., 59 ft. lbs.).
6. Install No.3, No.1 and No.2 cylinder head covers as follows:
(a) Remove any old packing (FIPG) material.






(b) Apply seal packing part No. 08826-00080, or equivalent, to the cylinder head as shown in the illustration.
(c) Install the gaskets to the No.1 and No.2 cylinder head covers.
(d) Install the No.1 cylinder head cover with the four bolts and tighten to: 8.3 Nm (85 kg. cm., 74 inch lbs.)
(e) Install the No.2 cylinder head cover with the four bolts and tighten to: 8.3 Nm (85 kg. cm., 74 inch lbs.).
(f) Install the No.3 cylinder head cover with the four bolts and four nuts and tighten to: 8.3 N m (85 kg. cm., 74 inch lbs.).
(g) Install the PCV valve.






7. Using a new gasket, install the intake manifold and delivery pipe assembly with the six bolts and two nuts, then tighten to: 27 Nm (280 kg. cm., 20 ft. lbs.).






8. Connect the fuel inlet pipe with two new gaskets and the union bolt, tighten to 42 Nm (420 kg. cm., 30 ft. lbs.), then install the clamp bolt to the intake manifold.
9. Install fuel pressure pulsation damper, refer to Powertrain Management.
10. Install intake manifold stay, then tighten to: 39 Nm (400 kg. cm., 29 ft. lbs.).
11. Install water outlet with water bypass hose, then tighten to: 21 Nm (210 kg. cm., 15 ft. lbs.).
12. Connect the following engine wiring:
(a) Install the engine wire protector to the intake manifold with the three nuts.
(b) Connect these connectors:
- Six injector connectors

NOTE: The No.1, No.3 and No.5 injector connectors are dark gray, and the No.2, No.4 and No.6 injector connectors are gray.

- Engine Coolant Temperature (ECT) sensor connector.
- ECT sender gauge connector.
- A/C compressor connector.
- Oil level sensor connector.
- Oil pressure switch connector.
- 2 knock sensor connectors.
(c) Install the wire clamp to the fuel return pipe.
(d) Install the two ground straps to the intake manifold with the bolts.
(e) Connect these connectors:
- Crankshaft position sensor connector.
- Heated oxygen sensor (bank one sensor 1) connector.
(f) Connect the wire clamp to the bracket.
13. Install timing belt.
14. Install spark plugs.
15. Install distributor and high-tension cords assembly, refer to Powertrain Management.
16. Connect high-tension cords (spark plug wires) to cylinder head covers.
17. Install No.3 timing belt cover.
18. Install cylinder head rear cover.
19. Install air intake chamber as follows:






(a) Install a new gasket and the intake chamber with the five bolts and nut, then tighten to: 27 Nm (280 kg. cm., 20 ft. lbs.).
(b) Install the bolt holding the engine wire protector to the air intake chamber.
(c) Connect the following hoses:
- Vacuum hose to brake booster union
- EVAP hose to No.2 vacuum pipe
20. Install Diagnostic Link Connector (DLC1) Bracket and Vacuum Switching Valve (VSV) Assembly.
21. Install vacuum control valve set, tighten to: 21 Nm (210 kg. cm., 15 ft. lbs.).
22. Install No.2 vacuum pipe and VSV assembly, tighten to: 27 Nm (280 kg. cm., 20 ft. lbs.).
23. Connect EGR gas temperature sensor connector.
24. Install oil dipstick and guide for engine.
25. Install oil dipstick and guide for transmission.
26. Install air intake chamber stays as follows:

NOTE: The No.1 stay is marked with "F", and No.2 stay is marked with "R".






(a) Install the No.1 stay with the bolt and nut, then tighten to: 18 Nm (185 kg. cm, 13 ft. lbs.).
(b) Install the No.2 stay with the bolt and nut, tighten to: 18 Nm (185 kg. cm., 13 ft. lbs.).
27. Install throttle body and intake air connector assembly, refer to Powertrain Management.
28. Install engine wire bracket.
29. Connect fuel return hose.
30. Install Power Steering (PS) pump as follows:
(a) Install the pump rear stay with the two bolts, then tighten to: 39 Nm (400 kg. cm., 29 ft. lbs.).
(b) Install the vane pump with the two bolts, then tighten to: 58 Nm (590 kg. cm., 43 ft. lbs.).
(c) Connect the following hoses:
- PS air hose to No.4 timing belt cover
- PS air hose to air intake chamber
31. Install No.1 water bypass pipe and water bypass outlet, refer to Cooling System.
32. Install exhaust manifolds as follows:
(a) Install new gaskets and the exhaust manifolds with new nuts, tighten to: 39 Nm (400 kg. cm., 29 ft. lbs.).
(b) Connect the two heated oxygen sensor connectors.
33. Install No.2 front exhaust pipe, refer to Exhaust System.
34. Install the drive belt by turning the drive belt tensioner clockwise.
35. Install air cleaner, Mass Air Flow (MAF) meter and intake air connector pipe assembly.
36. Install air cleaner duct.
37. Fill with engine coolant.
38. Start engine and check for leaks.
39. Check ignition timing, refer to Powertrain Management.
40. Install engine under cover.
41. Road test. check for abnormal noise, shock, slippage, correct shift points and smooth operation.
42. Check engine coolant level.