Installation
Installation
CAUTION:
^ After removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike piston heads.
^ When installing rocker arms, camshafts, chain tensioner, oil seals, or other sliding parts, lubricate contacting surfaces with new engine oil.
^ Apply new engine oil to bolt threads and seat surfaces when installing cylinder head, camshaft sprockets, crankshaft pulley, and camshaft brackets.
1. Install crankshaft sprocket on crankshaft.
^ Make sure that mating marks on crankshaft sprocket face front of engine.
Fig. 9 Timing Chain Alignment:
2. Position crankshaft so that No. 1 piston is set at TDC and key way is at 12 o'clock. Fit timing chain on crankshaft sprocket, aligning the mating marks.
^ Mating mark color on timing chain.
1: Yellow
2, 3: Blue
3. Install timing chain and timing chain guides.
4. Use a scraper to remove old liquid gasket from mating surface of front cover.
^ Also remove old liquid gasket from mating surface of cylinder block.
5. Apply a continuous bead of liquid gasket to front cover.
^ Use Genuine RTV silicone sealant part No. 999MP-A7007 or equivalent.
Be sure to install new front oil seal in the right direction.
6. Install oil pump drive spacer and front cover.
^ Wipe off excessive liquid gasket.
7. Install RH engine mounting and bracket.
8. Install generator.
9. Install crankshaft pulley.
10. Set No. 1 piston at TDC of its compression stroke.
11. Install oil strainer.
12. Install aluminum oil pan.
13. Before installing cylinder head gasket, apply liquid gasket as shown in the illustration.
Fig. 10 Cylinder Head Bolt Dimension:
14. 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: If cylinder head bolt exceeds limit of dimension "A", replace it.
Dimension 158.2 mm (6.228 inch)
15. Tighten cylinder head bolts using the following procedure.
a. Tighten all bolts to 39 Nm (4.0 kg-m, 29 ft. lbs.).
b. Tighten all bolts to 78 Nm (8.0 kg-m, 58 ft. lbs.).
c. Loosen all bolts completely.
d. Tighten all bolts to 34 to 44 Nm (3.5 to 4.5 kg-m, 25 to 33 ft. lbs.).
e. Method A:
Turn all bolts 90 to 95 degrees clockwise with Tool or suitable angle wrench.
Method B:
If an angle wrench is not available, mark all cylinder head bolts on the side facing engine front. Then, turn each cylinder head bolt 90 to 95 degrees clockwise.
f. Turn all bolts another 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.
16. Install cylinder head outside bolts.
17. Install the following water hoses:
^ Water hose for cylinder block.
^ Water hoses for heater.
18. Install starter motor.
19. Remove old liquid gasket from mating surface of LH camshaft end bracket.
^ Also remove old liquid gasket from mating surface of cylinder head.
20. Apply liquid gasket to mating surface of LH camshaft end bracket as shown in illustration.
^ Use Genuine RTV silicone sealant part No. 999MP-A7007 or equivalent.
21. Install camshafts, camshaft brackets.
^ Position camshaft.
^ LH camshaft key at about 12 o'clock.
^ RH camshaft key at about 12 o'clock.
Apply new engine oil to bearing and cam surfaces of camshafts before installing them.
^ Position camshaft brackets as shown in the illustration.
Apply new engine oil to threads and seating surfaces of camshaft bracket bolts before installing them.
^ Arrange bolts (Size and length).
A: M6 x 53.8 mm (2.12 inch)
B: M6 x 37 mm (1.46 inch)
C: M6 x 35 mm (1.38 inch)
^ Tightening procedure
STEP 1:
RH camshaft
Tighten bolts 9 - 10 in that order then tighten bolts 1 - 8 in numerical order.
Tightening Torque: 2 Nm (0.2 kg-m, 17 inch lbs.)
LH camshaft
Tighten bolts 11 - 12 in that order then tighten bolts 1 - 10 in numerical order.
Tightening Torque: 2 Nm (0.2 kg-m, 17 inch lbs.)
STEP 2:
Tighten bolts in numerical order.
Tightening Torque: 6 Nm (0.6 kg-m, 52 inch lbs.)
STEP 3:
Tighten bolts in numerical order.
Bolt type A B D
Tightening Torque: 9.8 - 11.8 Nm (1.0 - 1.2 kg-m, 7.2 - 8.7 ft. lbs.)
Bolt type C
Tightening Torque: 18 - 25 Nm (1.8 - 2.6 kg-m, 13 - 19 ft. lbs.)
22. Install camshaft sprockets and timing chain on them. Line up mating marks on timing chain with mating marks on camshaft sprockets.
^ Lock camshafts as shown in figure and tighten to specified torque.
137 - 157 Nm (14.0 - 16.0 kg-m, 101 - 116 ft. lbs.)
Apply new engine oil to threads and seating surfaces of camshaft sprocket bolts before installing them.
23. 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 for rotor is set at No. 1 cylinder spark position.
Fig. 19 Chain Tensioner Installation:
24. 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.
25. Install thermostat housing with water pipe.
26. Install intake manifold supports.
27. Remove old liquid gasket from mating surfaces of rocker cover and cylinder head.
28. Apply a continuous bead of liquid gasket to rocker cover gasket and cylinder head as shown in the illustrations.
^ Use Genuine RTV silicone sealant Part No. 999MP-A7007 or equivalent.
29. Install rocker cover and oil separator.
^ Be sure to install washers between bolts and rocker cover.
^ Tightening procedure
STEP 1: Tighten bolts 1 - 10 - 11 - 13 - 8 in that order.
STEP 2: Tighten bolts 1 - 13 in that order.
Tightening Torque: 8 - 10 Nm (0.8 - 1.0 kg-m, 69 - 87 inch lbs.)
30. Install the following parts:
^ Spark plugs and leads
^ Power steering pump
^ ASCD actuator
^ Water pump pulley and drive belts.
^ Radiator
Refit hoses and refill with coolant.
^ Front RH wheel
^ Engine under covers
31. Connect the following:
^ Vacuum hoses
^ Fuel hoses
^ Wire harnesses and connectors
^ Air duct to intake manifold