Installation
CYLINDER HEADS INSTALLATION1. Install cylinder heads
A. Place cylinder head on cylinder block
(a) Place 2 new cylinder head gaskets in position on the cylinder block.
NOTE: Be careful of the installation direction.
(b) Place the 2 cylinder heads in position on the cylinder head gaskets.
B. Install 12 pointed head cylinder head bolts
HINT:
The cylinder head bolts are tightened in 2 progressive steps.
If any bolt is broken or deformed, replace it.
(a) Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
(b) Install the plate washer to the cylinder head bolt.
(c) Install and uniformly tighten the cylinder head bolts on each cylinder head, in several passes to 40 ft.lbs in the sequence shown, then repeat for the other side.
If any of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt.
(d) Mark the front of the cylinder head bolt head with paint.
(e) Retighten the cylinder head bolts by 90° in the numerical order shown.
(f) Check that the painted mark is now at a 90° angle to the front.
C. Install recessed head cylinder head bolts
(a) Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
(b) Using an 8 mm hexagon wrench. install the cylinder head bolt on each cylinder head. then repeat for the other side. as shown.
Torque: 18.5 N.m (185 kgf.cm. 13 ft.lb)
2. Assemble exhaust camshafts
(a) Mount the hexagonal wrench head portion of the camshaft in a vise.
NOTE: Be careful not to damage the camshaft.
(b) Install these parts:
(1) Camshaft gear spring
(2) Camshaft sub-gear
HINT: Attach the pins on the gears to the gear spring ends.
(3) Wave washer
(c) Using snap ring pliers, install the snap ring.
(d) Using SST, align the holes of the camshaft main gear and sub-gear by turning camshaft sub-gear counterclockwise, and temporarily install a service bolt.
SST 09960-10010 (09962-01000, 09963-00500)
(d) Align the gear teeth of the main gear and sub-gear, and tighten the service bolt.
3. Install camshafts
NOTE: Since the thrust clearance of the camshaft is small, the camshaft must be held level while it is being installed. If the camshaft is not level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged. causing the camshaft to seize or break. To avoid this, the following steps should be carried out.
A. Install exhaust camshaft of RH cylinder head
(a) Apply new engine oil to the thrust portion and journal of the camshaft.
(b) Place the exhaust camshaft at 90° angle of timing mark (2 dot marks) on the cylinder head.
(c) Apply MP grease to a new oil seal lip.
(d) Install the oil seal to the camshaft.
(e) Remove any old packing (FIPG) material.
(f) Apply seal packing to the No.1 bearing cap as shown.
Seal packing: Part No.08826-00080 or equivalent
(g) Install the 5 bearing caps in their proper locations.
(h) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
(i) Install and uniformly tighten the 10 bearing cap bolts, in several passes, in the sequence shown.
Torque: 16 N.m (160 kgfcm, 12 ft.lb)
B. Install intake camshaft of RH cylinder head
(a) Apply new engine oil to the thrust portion and journal of the camshaft.
(b) Align the timing marks (2 dot marks) of the camshaft drive and driven gears.
(c) Place the intake camshaft on the cylinder head.
(d) Install the 5 bearing caps in their proper locations.
(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 10 bearing cap bolts, in several passes, in the sequence shown.
Torque: 16 N.m (160 kgfcm, 12 ft.lb)
(g) Remove the service bolt.
C. Install exhaust camshaft of LH cylinder head
(a) Apply MP grease to the thrust portion of the camshaft.
(b) Place the intake camshaft at 90° angle of timing mark (1 dot mark) on the cylinder head.
(c) Apply MP grease to a new oil seal lip.
(d) Install the oil seal to the camshaft.
(e) Remove any old packing (FIPG) material.
(f) Apply seal packing to the No.1 bearing cap as shown.
Seal packing: Part No.08826-00080 or equivalent
(g) Install the 5 bearing caps in their proper locations.
(h) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
(i) Install and uniformly tighten the 10 bearing cap bolts, in several passes, in the sequence shown.
Torque: 16 N.m (160 kgf.cm, 12 ft.lb)
D. Install intake camshaft of LH cylinder head
(a) Apply MP grease to the thrust portion of the camshaft.
(b) Align the timing marks (1 dot mark) of the camshaft drive and driven gears.
(c) Place the intake camshaft on the cylinder head.
(d) Install the 5 bearing caps in their proper locations.
(e) Apply a light coat of engine oil on the threads and under the heads of bearing cap bolts.
(f) Install and uniformly tighten the 10 bearing cap bolts, in several passes, in the sequence shown.
Torque: 16 N.m (160 kgf.cm, 12 ft. lb.)
(g) Remove the service bolt.
4. Check and adjust valve clearance
Turn the camshaft and position the cam lobe upward, and check and adjust the valve clearance.
5. Install semi-circular plugs
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the semi-circular plug grooves.
Seal packing: Part No.08826-00080 or equivalent
(c) Install the 4 semi - circular plugs to the cylinder heads.
6. INSTALL CAMSHAFT POSITION SENSOR
(a) Install a new gasket to the position sensor.
(b) Install the position sensor with the 2 bolts.
Torque: 8 N.m (80 kgf.cm, 69 in.lb)
7. Install cylinder head covers
(a) Apply seal packing to the cylinder heads as shown in the illustration.
Seal packing: Part No.08826-00080 or equivalent
(b) Install the gasket to the cylinder head cover.
(c) Install the cylinder head cover with the 8 bolts. Uniformly tighten the bolts in several passes. Install the 2 cylinder head covers.
Torque: 8 N.m (80 kgf.cm, 69 in..lb)
8. Install right hand exhaust manifold
(a) Install a new gasket and the exhaust manifold with the 6 nuts.
Torque: 49 N.m (500 kgf.cm. 36 ft.lb)
(b) Install the exhaust manifold stay with the bolt and nut.
Torque: 20 N.m (200 kgf.cm, 15 ft.lb)
(c) Install 2 new gaskets and the No.1 EGR pipe with the 4 nuts.
Torque: 12 N.m (120 kgfcm, 9 ft.lb)
(d) Install the heated oxygen sensor.
Torque: 44 N.m (450 kgf.cm. 33 ft.lb)
9. Install ps bracket
Torque: 43 N.m (440 kgf.cm, 32 ft.lb)
10. Install oil dipstick and guide
(a) Install a new 0-ring to the dipstick guide.
(b) Apply soapy water to the 0-ring.
(c) Push in the dipstick guide end into the guide hole of the No.1 oil pan.
(d) Install the dipstick guide with the bolt.
Torque: 8 N.m (80 kgf.cm, 69 in.lb)
(e) Install the dipstick.
11. Install left hand exhaust manifold
(a) Install a new gasket and the exhaust manifold with the 6 nuts.
Torque: 49 N.m (500 kgf.cm. 36 ft.lb)
(b) Install the exhaust manifold stay with the bolt and nut.
Torque: 20 N.m (200 kgf.cm, 15 ft.lb)
(c) Install the heated oxygen sensor.
Torque: 44 N.m (450 kgf.cm, 33 ft.lb)
12. Install water outlet
(a) Connect the water outlet to the bypass hose.
(b) Install 2 new gaskets and the water outlet with the 2 bolts, 2 nuts and 2 plate washers.
Torque: 15 N.m (150 kgf.cm, 11 ft.lb)
NOTE: Do not scratch the seal surface of the water outlet with the stud bolt.
13. Install injectors and delivery pipes
(a) Install 2 new grommets to each injector.
(b) Apply a light coat of gasoline to 2 new 0-rings and install them to each injector.
(c) While turning the injector clockwise and counter clockwise, push it to the delivery pipes. Install the 6 injectors.
(d) Position the injector connector outward.
(e) Place the 4 spacers in position on the intake manifold.
(f) Place the delivery pipes together with the 6 injectors in position on the intake manifold.
(g) Temporarily install the 4 bolts holding the delivery pipes to the intake manifold.
(h) Check that the injectors rotate smoothly.
HINT: If injectors do not rotate smoothly. the probable cause is incorrect installation of 0-rings. Replace the 0-rings.
(i) Position the injector connector outward.
(j) Tighten the 4 bolts holding the delivery pipes to the intake manifold.
Torque:
Pulsation damper: 32.5 N.m (330 kgf.cm, 24 ft.lb)
Bolt: 15 N.m (150 kgf.cm, 11 ft.lb)
16. Install fuel pressure regulator
17. Install intake manifold
Install the intake manifold with the 9 bolts, 2 nuts and 2 plate washers. Uniformly tighten the bolts and nuts, in several passes, in the sequence shown.
Torque: 15 N.m (150 kgf.cm, 11 ft.lb)
18. Retighten water outlet mounting bolts and nuts
Torque: 15 N.m (150 kgf.cm, 11 ft.lb)
19. Install air assist hose
20. Install water inlet pipe
(a) Install a new 0-ring to the water inlet pipe.
(b) Apply soapy water to the 0-ring.
(c) Connect the water inlet pipe to the water inlet.
(d) Install the bolt holding the water inlet pipe to the cylinder head.
Torque: 19.5 N.m (200 kgf.cm, 14 ft.lb)
21. Install cylinder head rear plate
(a) Install the rear plate and ground strap with the bolt and nut.
Torque: 8 N.m (80 kgf.cm, 69 in.lb)
(b) Connect the vacuum hose to the air intake chamber.
(c) Connect the 2 vacuum hoses to the vacuum tank.
22. Install no.3 timing belt cover
(a) Check that the timing belt cover gaskets have no cracks or peeling, etc.
If the gaskets have cracks or peeling etc., replace them using these steps:
- Using a screwdriver and gasket scraper, remove all the old gasket material.
- Thoroughly clean all components to remove all the loose material.
- Remove the backing paper from a new gasket and install the gasket evenly to the part of the timing belt cover shaded black in the illustration.
NOTE: When joining 2 gaskets, do not leave a gap between them. Cut off any excess gasket.
- After installing the gasket, press down on it so that the adhesive firmly sticks to the timing belt cover.
(b) Install the timing belt cover with the 6 bolts.
Torque: 8.5 N.m (85 kgf.cm, 74 in.lb)
23. Install no.2 idler pulley
24. Install right hand camshaft timing pulley
25. Install left hand camshaft timing pulley
26. Install timing belt
27. Install front exhaust pipe
(a) Temporarily install 3 new gaskets and the front exhaust pipe with the 2 bolts and 6 nuts.
(b) Tighten the 4 nuts holding the exhaust manifolds to the front exhaust pipe.
Torque: 62 N.m (630 kgf.cm, 46 ft.lb)
(c) Tighten the 2 bolts and 2 nuts holding the center exhaust pipe to the front exhaust pipe.
Torque: 56 N.m (570 kgf.cm, 41 ft.lb)
(d) Install the bracket with the 2 bolts.
Torque: 19 N.m (195 kgf.cm, 14 ft.lb)
(e) Install the stay with the 2 bolts.
Torque: 29.4 N.m (300 kgf.cm, 22 ft.lb)
28. Install spark plugs
Using a 16 mm plug wrench, install the 6 spark plugs to the RH and LH cylinder heads.
29. Install ignition coils
30. Connect engine wire to engine right hand side
Connect the engine wire with the 5 nuts.
31. Connect engine wire to engine rear side
Connect the engine wire with the 2 nuts.
32. Connect engine wire to no.3 timing belt cover
Connect the engine wire with the 2 clamps.
33. Connect engine wire to engine left hand side
Connect the engine wire with the 2 nuts.
34. Install EGR valve and vacuum modulator to air intake chamber
Install a new gasket. the EGR valve and vacuum modulator with the 3 nuts.
Torque: 12 N.m (120 kgf.cm, 9 ft.lb)
35. Install throttle body to air intake chamber
(a) Place a new gasket on the air intake chamber.
(b) Install the throttle body with the 2 bolts and 2 nuts.
Torque: 19.5 N.m (200 kgf.cm, 14 ft.lb)
36. Install intake air control valve to air intake chamber
(a) Install a new gasket to the air intake chamber.
(b) Apply a light coat of engine oil to the rubber portions.
(c) Apply seal packing to the positions of the intake air control valve as shown in the illustration.
Seal packing: Part No.08826-00080 or equivalent
(d) Install the intake air control valve and DLC1 clamp with the 3 nuts.
Torque: 14.5 N.m (145 kgf.cm, 10 ft.lb)
(e) Connect the A/C air hose.
37. Install air intake chamber
(a) Using an 8 mm hexagon wrench, install a new gasket and the air intake chamber with the 2 bolts and 2 nuts.
Torque: 43 N~m (440 kgf.cm, 32 ft.lb)
(b) Install 2 new gaskets and No.2 EGR pipe with the 4 nuts.
Torque: 12 N.m (120 kgf.cm, 9 ft.lb)
(c) Install the air intake chamber stay with the 2 bolts.
Torque: 19.5 N.m (200 kgf.cm, 14 ft.lb)
(e) Connect the PS pressure tube with the 2 nuts.
(f) Connect the ground strap with the bolt.
(g) Connect the hydraulic pressure pipe to the air intake chamber with the bolt.
(h) Connect the brake booster vacuum hose.
(i) Connect the PCV hose.
(j) Connect the DLC1.
(k) Connect the 2 ground straps with the nut.
Torque: 14.5 N.m (145 kgf.cm, 10 ft.lb)
38. Install emission control valve set
(a) Install the emission control valve set with the 2 bolts.
Torque: 8 N.m (80 kgf.cm, 69 in.lb)
(b) Connect these connectors:
(1) VSV connector for ACIS
(2) VSV connector for fuel pressure control
(3) VSV connector for EGR
(4) VSV connector for EVAP
(c) Connect these vacuum hoses:
(1) Vacuum hose to VSV for fuel pressure control
(2) Vacuum hose to fuel pressure regulator
(3) Vacuum hose to cylinder head rear plate
(4) Vacuum hose to VSV for ACIS
(5) Vacuum hose to EGR vacuum modulator
(6) Vacuum hose to EGR valve
(7) Vacuum hose from air intake chamber
(8) Vacuum hose from charcoal canister
39. Install high-tension cords and high-tension cord cover
(a) Install the high-tension cords.
(b) Install the holder, grommet and high-tension c
40. Install V-bank cover
Using a 5 mm hexagon wrench, install the V-bank cover with the 2 nuts.
41. Connect pressure hose to hydraulic motor
Connect the pressure hose to the water inlet.
42. Connect fuel hoses
(a) Connect the fuel return hose to the fuel pipe.
(b) Connect the fuel inlet hose to the fuel filter.
Torque: 29 N.m (300 kgf.cm, 21 ft. lb)
43. Connect heater hoses
Connect the 2 hoses.
44. Connect radiator hoses
Connect the 2 hoses.
45. Install right hand engine mounting stay
Install the mounting stay with the 3 bolts.
Torque: 31.4 N.m (320 kgf.cm. 23 ft.lb)
46. Connect ground straps
47. With cruise control system:
Install cruise control actuator
48. Install air cleaner cap assembly
49. Connect alt throttle cable
50. Connect accelerator cable
51. Fill with engine coolant
52. Install battery tray and battery
53. Start engine and check for leaks
54. Vehicle road test
Check for abnormal noises, shock, slippage, correct shift points and smooth operation.
55. Recheck engine coolant level