Part 1

RH EXHAUST MANIFOLD TO CYLINDER HEAD INSTALLATION

1. Place a new gasket on the cylinder head with the white painted marks facing the manifold side.

NOTE: Be careful of the installation direction.

2. Install the exhaust manifold with eight new nuts, uniformly tighten the nuts in several passes to 44 Nm (450 kg.cm, 32 ft.lb).
3. Install the heat insulator with the three bolts.

LH EXHAUST MANIFOLD TO CYLINDER HEAD INSTALLATION

1. Place a new gasket on the cylinder head with the white painted marks facing the manifold side.

NOTE: Be careful of the installation direction.

2. Install the exhaust manifold with eight new nuts, uniformly tighten the nuts in several passes to 44 Nm (450 kg.cm, 32 ft.lb).
3. Install the heat insulator with the three bolts.

CYLINDER HEAD WITH EXHAUST MANIFOLD INSTALLATION
1. Install bearing cap and seal plug to LH cylinder head as follows:

Fig. 26 Seal Packing Locations:

(a) Remove any old seal packing (FIPG) material.
(b) Apply seal packing Part No. 08826-00080, or equivalent, to the bearing caps as shown.

(c) Place a new camshaft housing plug on the cylinder head, facing the cup side forward.
(d) Install the bearing cap (mark "I6") in position with the arrow mark facing forward.
(e) Install a new seal washer to the bearing cap bolt.
(f) Apply a light coat of engine oil on the threads of the bearing cap bolt.
(g) Install the two bearing cap bolts. Alternately tighten bearing cap bolts to 16 Nm (160 kg.cm, 12 ft.lb).

NOTE: Use silver colored bolts 38 mm (1.50 inch) in length.

2. Install cylinder head assemblies to cylinder block as follows:

(a) Place two new cylinder head gaskets in position on the cylinder block.

NOTE:
- On the rear side of the cylinder head gasket are painted marks to distinguish the LH and RH banks, a white painted mark for the RH bank and a yellow painted mark for the LH bank.
- Be careful of the installation direction.

(b) Place the two cylinder heads in position on the cylinder head gaskets.

(c) Using the sequence shown and in several passes, install and uniformly tighten the 10 cylinder head bolts with plate washers to 39 Nm (400 kg.cm, 29 ft.lb) on one cylinder head, then repeat on the other side.

NOTE:
- If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt.
- If any cylinder head bolt is broken or deformed, replace it.
- Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.

CAUTION:
- Do not drop the plate washer for cylinder head bolt into location marked A in the illustration.
- If dropped into location A, the plate washer will pass through the cylinder head and cylinder block into the oil pan.

(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 front.
3. Install bearing cap and seal plug to RH cylinder head as follows:

Fig. 26 Seal Packing Locations:

(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the bearing caps as shown.
(c) Place a new camshaft housing plug on the cylinder head, facing the cup side forward.

(d) Install the bearing cap (mark "I1") in position with the arrow mark facing rearward.
(e) Install a new seal washer to the bearing cap bolt.
(f) Apply a light coat of engine oil on the threads of the bearing cap bolt.
(g) Install the two bearing cap bolts. Alternately tighten bearing cap bolts to 16 Nm (160 kg.cm, 12 ft.lb).

NOTE: Use silver colored bolts 38 mm (1.50 in) in length.
4. Install engine wiring as follows:

(a) Install the engine wire to the RH cylinder head with the two bolts.
(b) Install the ground cable to RH cylinder head with the bolt.

(c) Install the engine wire protector to the LH cylinder head with the bolt.
(d) Install the ground cable to LH cylinder head with the bolt.
(e) Connect the two heated oxygen sensor connectors.
5. Install spark plugs.
6. Assemble exhaust camshaft as follows:

(a) Install these parts as shown in the illustration:
- Camshaft gear spring (1).
- Camshaft sub-gear (2).

NOTE: Attach the pins on the gears to the gear spring ends.

- Wave washer (3).

(b) Using snap ring pliers, install the snap ring.

(d) Using variable pin wrench Special Service Tool (SST) No. 09960-10010, or equivalent, align the holes of the camshaft main gear and sub-gear by turning camshaft sub-gear counterclockwise, and temporarily install a service bolt.
(e) Align the gear teeth of the main gear and sub-gear, and tighten the service bolt.

CAMSHAFT INSTALLATION

CAUTION: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept 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.

1. Turn the crankshaft pulley clockwise or counterclockwise, and put the timing mark of the crankshaft pulley in line with the centers of the crankshaft pulley bolt and the idler pulley bolt.

NOTE: Having the crankshaft pulley at the wrong angle can cause the piston head and valve head to come into contact with each other when you install the camshaft, causing damage. So always set the crankshaft pulley at the correct angle.

2. Install RH intake camshaft as follows:
(a) Apply MP grease to the thrust portion of the intake camshaft.

(b) Place the intake camshaft at 45° angle of the timing mark (1 dot mark) on the cylinder head.

(e) Install the front bearing cap (mark "I6" ) with the arrow mark facing rearward.

NOTE:
- Installing the front bearing cap will determine the thrust portion of the camshaft.
- Align the arrow marks at the front and rear of the cylinder head with the mark on the bearing cap.

(f) Install the other bearing cap in the sequence shown with the arrow mark facing rearward.

NOTE: Align the arrow marks at the front and rear of the cylinder head with the mark on the bearing cap.

(g) Apply a light coat of engine oil on the threads and under the heads (A in illustration only) of the bearing cap bolts.

NOTE: Do not apply engine oil under the heads of the bearing cap bolt (B in illustration).

(h) Install a new seal washer to the bearing cap bolt (B in illustration), install the eight bearing cap bolts as shown.

NOTE:
- Use bearing cap bolts 38 mm (1.50 in) in length. The bolts are black (A) or silver (B) in color.
- Install the two silver bolts to the front bearing cap. Install the six black bolts to the other positions.
- After installing the oil feed pipe, install the two bolts to rear bearing cap as directed below.

(i) Using sequence shown uniformly tighten the eight bearing cap bolts in several passes to 16 Nm (160 kg.cm, 12 ft.lb).

3. Install RH exhaust camshaft as follows:

(a) Set the timing mark (1 dot mark) of the camshaft drive gear at 10° angle by turning the hexagon wrench head portion of the intake camshaft with a wrench.
(b) Apply MP grease to the thrust portion of the exhaust camshaft.

(c) Align the timing marks (1 dot mark) of the camshaft drive and driven gears.
(d) Place the exhaust camshaft on the cylinder head.
(e) Check that the exhaust camshaft moves smoothly in the thrust direction.

(f) Install the rear bearing cap (mark "E1") with the arrow mark facing rearward.

NOTE:
- Installing the rear bearing cap will determine the thrust portion of the camshaft.
- Align the allow marks at the front and rear of the cylinder head with the mark on the bearing cap.

(g) Install the other bearing cap in the sequence shown with the arrow mark facing rearward.

NOTE: Align the arrow marks at the front and rear of the cylinder head with the mark on the bearing cap.

(h) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
(i) Install the oil feed pipe and 10 bolts.

NOTE: Use bearing cap bolts 38 mm (1.50 in) and 52 mm (2.05 in) in length. Use black colored 38 mm (1.50 in) bolts. Install the two 52 mm (2.05 in) bolts in outside positions of the oil feed pipe. Install the eight 38 mm (1.50 in) bolts in the other positions.

(j) Using the sequence shown uniformly tighten the eight bolts on the bearing caps of the exhaust camshaft in several passes to 16 Nm (160 kg.cm, 12 ft.lb).

(k) Alternately tighten the two bolts on the rear bearing caps of the intake camshaft in several passes to 16 Nm (160 kg.cm, 12 ft.lb).

(l) Bring the service bolt installed in the driven sub-gear upward by turning the hexagon wrench head portion of the camshaft with a wrench.
(m) Remove the service bolt.