Cylinder Head Assembly
CYLINDER HEAD SUB-ASSEMBLYHINT: The cylinder head bolts are tightened in 2 progressive steps.
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.
Install the bolts and plate washers to the cylinder head.
Using several steps, uniformly install and tighten the 10 cylinder head set bolts and plate washers with a 10 mm bi-hexagon wrench in the order shown in the illustration.
Torque: 70 Nm (714 kgf-cm, 52 ft-lbf)
Mark the front side of the cylinder head bolt with paint.
Retighten the cylinder head bolts 90° in the sequence shown in the illustration.
Check that the paint mark is now at a 90° angle to the front.
CYLINDER HEAD SET BOLT
Standard bolt length: 141.3 to 142.7 mm (5.563 to 5.618 in.)
Maximum bolt length: 144.2 mm (5.677 in.)
CYLINDER HEAD FLATNESS
Maximum warpage:
Cylinder block surface: 0.05 mm (0.0020 in.)
Intake manifold surface 0.08 mm (0.0031 in.)
Exhaust manifold surface 0.08 mm (0.0031 in.)
INTAKE MANIFOLD
Install a new gasket and the intake manifold with the 5 bolts and 2 nuts.
Torque: 30 Nm (306 kgf-cm, 22 ft-lbf)
THROTTLE BODY ASSEMBLY
Install the throttle body and fuel pipe support with the 4 bolts.
Torque: 30 Nm (305 kgf-cm, 22 ft-lbf)
EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY
Install a new gasket and the exhaust manifold converter with the 5 nuts. Uniformly tighten the 5 nuts in the sequence shown in the illustration.
Torque 37 Nm (378 kgf-cm, 27 ft-lbf)
CAMSHAFT TIMING GEAR ASSEMBLY
Put the camshaft timing gear against the camshaft.
Turn the camshaft timing gear (in the direction shown in the illustration) while pushing it lightly against the camshaft. Push further at the position where the pin gets into the groove.
NOTE: Be sure not to turn the camshaft timing gear to the retarded angle side (to the right direction).
Check that there is no clearance between the gear's fringe and the camshaft.
Tighten the fringe bolt with the camshaft timing gear fixed.
Torque: 54 Nm (551 kgf-cm, 40 ft-lbf)
Check that the camshaft timing gear can move to the retarded angle side (to the right direction) and is locked at the extreme retarded angle.
INSTALL CAMSHAFT
Examine the front marks and numbers of the 5 bearing caps and install them. Then install the 10 bearing cap bolts. Uniformly tighten the bolts in the sequence shown in the illustration.
Bearing cap No.1 - Torque: 30 Nm (301 kgf-cm, 22 ft-lbf)
Bearing cap No.3 - Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
NO.2 CAMSHAFT
Examine the front marks and numbers of the 5 bearing caps and install them. Then install the 10 bearing cap bolts. Uniformly tighten the bolts in the sequence shown in the illustration.
Bearing cap No.2 - Torque: 30 Nm (301 kgf-cm, 22 ft-lbf)
Bearing cap No.3 - Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)