Installation

INSTALLATION

HINT:
- Thoroughly clean all parts to be assembled.
- Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
- Replace all gaskets and oil seals with new ones.

1. INSTALL CYLINDER HEAD





a. Place the cylinder head on the cylinder block.
1) Place a new cylinder head gasket on the cylinder block surface with the lot No. upward.

NOTICE: Be careful of the installation direction.

2) Place the cylinder head quietly in order not to damage the gasket with the bottom part of the head.
b. Install the cylinder head bolts.

NOTE: The head bolts should be replaced if they are not within specifications. For specifications, see Cylinder Head Torque & Sequence

HINT:
- The cylinder head bolts are tightened in 2 steps (steps (2) and (4)).
- If any cylinder head bolt is broken or deformed, replace it.

1) Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.





2) Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 10 cylinder head bolts and plate washers in several passes, in the sequence shown.
Torque: 79 Nm (800 kgf-cm, 58 ft. lbs.)
If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt.





3) Mark the front of the cylinder head bolt with paint.
4) Retighten the cylinder head bolts 90° in the numerical order shown.
5) Check that the painted mark is now at a 90° angle to the front.
2. INSTALL CAMSHAFTS





a. Install the lower camshaft bearing to the cylinder head.





b. Align the bearing claw with the claw groove of No. 1 bearing cap, and push in the upper camshaft bearing.





c. Place the 2 camshafts on the cylinder head with the No. 1 cam lobes facing as shown the illustration.





d. Install the bearing caps in their proper locations.

HINT:
- Each of No. 3 camshaft bearing cap has a number and front mark.
- The No. 1 and No. 2 bearing caps has a front marks.

e. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.





f. Install and uniformly tighten the 20 bearing cap bolts in several passes, in the sequence shown.
Torque:
29.5 Nm (300 kgf-cm, 22 ft. lbs.) for No. 1 and No. 2
9.0 Nm (92 kgf-cm, 80 inch lbs.) for others





3. CHECK AND ADJUST VALVE CLEARANCE

NOTICE: Under the condition with the timing chain cover removed, in case of rotating the camshafts, make the position of the crankshaft rotated clockwise by about 45° from TDC/compression of No. 1 cylinder.

Turn the camshafts and position the cam lobe upward, and check and adjust the valve clearance.
4. INSTALL CAMSHAFT TIMING SPROCKET AND VVT TIMING SPROCKET
5. INSTALL TIMING CHAIN
6. INSTALL CAMSHAFT POSITION SENSOR
7. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE (OCV)
8. INSTALL OIL FILLER CAP
9. CONNECT ENGINE WIRE TO CYLINDER HEAD
a. Install the 2 ground cables with the 2 bolts.
b. Connect the noise filter connector.
c. Connect the oil control valve connector.
d. Connect the oil pressure switch connector.
e. Connect the camshaft position sensor connector.
f. Connect the water temperature sensor connector.





10. INSTALL INTAKE MANIFOLD
a. Install the intake manifold insulator to the cylinder block.
b. Connect the engine wire harness clamp.
c. Install a new gasket to the intake manifold.
d. Install the intake manifold with the 5 bolts and 2 nuts.
Torque: 30 Nm (305 kgf-cm, 22 ft. lbs.)
e. Install the brake booster vacuum hose with the bolt.
f. Install the PCV hose.
11. INSTALL THROTTLE BODY
12. INSTALL INJECTOR
13. INSTALL EXHAUST MANIFOLD
a. Install a new gasket and the exhaust manifold with the 5 bolts and 2 nuts.
Torque: 37 Nm (380 kgf-cm, 27 ft. lbs.)
b. Install the No. 2 manifold convertor heat insulator with the bolt.
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)
c. Install the No. 1 manifold convertor heat insulator with the 3 bolts.
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)
d. Install the No. 2 exhaust manifold heat insulator with the 2 bolts.
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)
e. Install the No. 1 heat insulator with the 4 bolts.
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)
f. Install the 2 stays with the 3 bolts and 2 nuts.
Torque: 42 Nm (430 kgf-cm, 31 ft. lbs.)
g. Connect the heated oxygen sensor connector.
14. INSTALL ENGINE