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. PLACE CYLINDER HEAD ON CYLINDER BLOCK
a. Place a new cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.

NOTICE: Be careful of the installation direction.

b. Place the cylinder head quietly in order not to damage the gasket with the bottom part of the head
2. INSTALL CYLINDER HEAD BOLTS

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

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





b. 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: 49 Nm (500 kgf-cm, 36 ft. lbs.)
If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt.





c. Mark the front of the cylinder head bolt with paint.
d. Retighten the cylinder head bolts 90° in the numerical order shown.
e. Check that the paint mark is now at a 90° angle to the front.





f. Install the bolt holding the water bypass pipe to the cylinder head.
Torque: 9 Nm (92 kgf-cm, 80 inch lbs.)
g. Connect the upper radiator hose to the water hose unions.
h. Connect the heater hose to the water hose unions.
3. INSTALL CAMSHAFTS





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





b. Install the bearing caps in their proper locations.

HINT: No. 3 camshaft bearing cap has a number and front mark.

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





d. Install and uniformly tighten the 19 bearing cap bolts. After tightening the NO. 1 camshaft bearing cap, tighten then in several passes, in the sequence shown.
Torque:
23 Nm (235 kgf-cm, 17 ft. lbs.) for No. 1
13 Nm (133 kgf-cm, 10 ft. lbs.) for No. 3

HINT:
Bearing cap No. 1 - Illustration No. 9
Bearing cap No. 3 - Illustrations 1 to 8

4. CHECK AND ADJUST VALVE CLEARANCE
5. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE
6. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE FILTER
7. INSTALL CAMSHAFT TIMING SPROCKETS
8. INSTALL OIL FILLER CAP
9. INSTALL ECT SENSOR
10. INSTALL CAMSHAFT POSITION SENSOR
11. INSTALL ENGINE HANGER
Install the craw of the stopper pressing it on the stopper lib of the cylinder head.
Torque: 38 Nm (388 kgf-cm, 28 ft. lbs.)





12. INSTALL INTAKE MANIFOLD
a. Install a new gasket, the intake manifold and 2 brackets with the 2 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.
Torque: 18.5 Nm (189 kgf-cm, 14 ft. lbs.)
b. Install the manifold stay with the 2 bolts.
Torque: 18.5 Nm (189 kgf-cm, 14 ft. lbs.)
c. Install the hose clamp with the bolt and nut.
Torque: 18.5 Nm (189 kgf-cm, 14 ft. lbs.)
d. Connect the EVAP hose for ORVR.
e. Connect the brake booster vacuum hose.





13. CONNECT ENGINE WIRE TO CYLINDER HEAD
a. Install the engine wire protector to the 2 brackets on the intake manifold with the 2 bolts.
b. Connect the ECT sensor connector.
c. Connect the camshaft position sensor connector.
d. Connect the 2 ground wires.
14. INSTALL INJECTORS
15. INSTALL THROTTLE BODY
16. INSTALL PCV HOSES
17. INSTALL SPARK PLUGS
18. INSTALL IGNITION COILS





19. INSTALL EXHAUST MANIFOLD
a. Install the lower heat insulator to the exhaust manifold with the 3 bolts.
Torque: 12 Nm (123 kgf-cm, 9 ft. lbs.)
b. Install a new gasket and the exhaust manifold with the 5 nuts. Uniformly tighten the nuts in several passes.
Torque: 37 Nm (377 kgf-cm, 27 ft. lbs.)
c. Install the upper heat insulator with the 6 bolts.
Torque: 12 Nm (123 kgf-cm, 9 ft. lbs.)
d. Install the heat insulator to the dash panel with the bolt and 2 nuts.





20. INSTALL EXHAUST MANIFOLD STAY
Install the manifold stay with the 3 bolts. Alternately tighten the bolts.
Torque: 49 Nm (500 kgf-cm, 37 ft. lbs.)





21. CONNECT FRONT EXHAUST PIPE TO EXHAUST MANIFOLD
a. Place a new gasket to the exhaust manifold.
b. Install the 2 bolts and 2 springs holding the front exhaust pipe to the exhaust manifold.
Torque: 62 Nm (630 kgf-cm, 46 ft. lbs.)
c. Install a new gasket and the heated oxygen sensor with the 2 new nuts.
Torque: 20 Nm (200 kgf-cm, 14 ft. lbs.)
22. CONNECT ACCELERATOR CABLE
23. A/T: CONNECT THROTTLE CABLE
24. INSTALL AIR CLEANER HOSE
25. INSTALL GENERATOR AND DRIVE BELT
26. FILL WITH ENGINE COOLANT
27. START ENGINE AND CHECK FOR LEAKS
28. RECHECK ENGINE COOLANT LEVEL AND OIL LEVEL