Part 2

4. Install LH intake camshaft as follows:

(a) Apply MP grease to the thrust portion of the intake camshaft.
(b) Place the intake camshaft at 60° angle of the timing mark (1 dot mark) on the cylinder head.

(e) Install the front bearing cap (mark "I1") with the arrow mark facing forward.

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 forward.

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 (bolts shown as A in illustration only) of the bearing cap bolts.

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

(h) Install a new seal washer to the bearing cap bolt (bolts shown as 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 the bearing cap second from the front as directed below.

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

5. Install LH exhaust camshaft as follows:

(a) Set the timing mark (2 dot marks) of the camshaft drive gear at 15° 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 (2 dot marks) 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 front bearing cap (mark "E1") with the arrow mark facing forward.

NOTE:
- Installing the front 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 forward.

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 bearing cap of the intake camshaft second from the front 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.

6. Check and adjust valve clearance, refer to Camshaft, Lifters and Pushrods.

7. Using seal driver SST No. 09223-46011 and a suitable hammer, tap in the two camshaft oil seals.
8. Install semi-circular plugs to cylinder head as follows:

(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the semi-circular plug grooves as shown in the illustration.

(c) Install the four semi-circular plugs to the cylinder heads to positions shown.

CYLINDER HEAD COVER INSTALLATION
1. Install cylinder head covers as follows:
(a) Remove any old packing (FIPG) material.

(b) Apply seal packing to the cylinder heads as shown in the illustration.
(c) Install the gasket to the cylinder head cover.
(d) Install the seal washer to the eight bolts, then install the cylinder head cover with the bolts.
(e) Uniformly tighten the bolts in several passes.

(f) Install the two cylinder head covers tighten to 6.0 Nm (60 kg.cm, 53 inch lbs.).
2. Install engine hangers, tighten to 37 Nm (380 kg.cm, 27 ft.lb).
3. Install oil dipstick and guide for engine as follows:

(a) Install a new O-ring to the dipstick guide.
(b) Apply soapy water to the O-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.
(e) Install the dipstick.
4. Install oil dipstick and guide for Automatic Transmission (A/T) as follows:

(a) Install a new O-ring to the dipstick guide.
(b) Apply soapy water to the O-ring.
(c) Connect the dipstick guide end to the dipstick tube of the oil pan.
(d) Install the dipstick guide with the bolt.
(e) Install the dipstick.

WATER BYPASS HOUSING INSTALLATION

1. Install rear water bypass joint and No.1 EGR pipe assembly as follows:
(a) Install two new water bypass housing gaskets to the cylinder head.
(b) Install a new gasket to the RH exhaust manifold.
(c) Attach the water bypass joint and EGR pipe assembly to the cylinder heads and RH exhaust manifold.
(d) Install the four nuts holding the water bypass joint to the cylinder heads. Alternately tighten the nuts tighten to 18 Nm (185 kg.cm, 13 ft.lb).

(e) Install two new nuts holding the EGR pipe to the RH exhaust manifold and tighten to 22.5 Nm (230 kg.cm, 17 ft.lb).
(f) Connect the heater hose to the water bypass joint.
(g) Install the RH heat insulator (for the RH front Three Way Catalytic Converter (TWC)) with the two bolts.
(h) Install the RH heat insulator (for the RH front side of the front exhaust pipe) with the two bolts and nut.
2. Install front water bypass joint as follows:

(a) Install two new gaskets and the water bypass joint with the four nuts, then alternately tighten the nuts to 18 Nm (185 kg.cm, 13 ft.lb).
(b) Install the engine wire protector with the bolt.
(c) Attach the engine wire protector to the water bypass joint nut.
(d) Connect these connectors:
- ECT sensor connector.
- ECT sender gauge connector.
3. Install water inlet and inlet housing assembly as follows:
(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the water inlet housing and water pump.
- Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and soaring groove.
- Thoroughly clean all components to remove all the loose material.
- Using a non-residue solvent, clean both sealing surfaces.

(b) Apply seal packing to the sealing groove of water inlet housing as shown in the illustration as follows:
- Install a nozzle that has been cut to a 2-3 mm (0.08-0.20 in) opening.
- Parts must be assembled within five minutes of application. Otherwise the material must be removed and reapplied.
- Immediately remove nozzle from the tube and reinstall cap.
(c) Install a new O-ring to the water inlet housing.

(d) Apply soapy water on the O-ring.
(e) Push the water inlet housing end into the water pump hole.
(f) Connect the water bypass hose (from the IAC valve) to the water inlet housing.

(g) Install the water inlet and housing assembly, alternately tighten the two bolts. to 18 Nm (185 kg.cm, 13 ft.lb).

NOTE: Use bolts 25 mm (0.98 in) in length.

AIR INTAKE CHAMBER AND INTAKE MANIFOLD INSTALLATION
1. Install intake manifold assembly as follows:

(a) Place two new gaskets on the cylinder heads with white painted mark facing upward.

NOTE: Align the port holes of the gasket and cylinder head. Be careful of the installation direction.

(b) Place the intake manifold on the cylinder heads with the arrow mark facing forward.

NOTE: Be careful of the installation direction.

(c) Install and uniformly tighten the six bolts and four nuts in several passes to 18 Nm (185 kg.cm, 13 ft.lb).

NOTE: Use a bolt 30 mm (1.18 in) in length.

(d) Connect the eight injector connectors.

2. Install the fuel return pipe with the two bolts, then connect the fuel hose to the fuel pressure regulator.
3. Install engine wire to delivery pipe and rear water bypass joint as follows:

(a) Install these connectors:
- DLC1 to connector bracket on LH delivery pipe (1).
- 2 engine wire connectors to connector bracket on LH delivery pipe (2).
- Engine wire clamp to wire bracket on LH delivery pipe (3).
(b) Install the engine wire protector to the RH delivery pipe with the two bolts.
(c) Install the engine wire protector to the rear water bypass joint with the two bolts.
(d) Install the A/T throttle cable to the clamps on the engine wire protector and engine hanger.
3. Connect fuel return hose to fuel return pipe.
4. Connect fuel inlet hose to LH delivery pipe, refer to Powertrain Management.
5. Install air intake chamber assembly as follows:

(a) Place four new gaskets on the intake manifold.

NOTE: Gaskets can only be used twice before being replaced.

(b) Connect these hoses, and place the air intake chamber assembly on the intake manifold:
- PCV hose (from RH cylinder head) to throttle body (1).
- Water bypass hose (from Idle Air Control (IAC) valve) to water inlet housing (2) .

(c) Install the air intake chamber, Vacuum Switching Valve (VSV) for fuel pressure control (1) and VSV for EVAP (2) with the four bolts and eight nuts, then uniformly tighten the bolts and nuts several passes to 18 Nm (185 kg.cm, 13 ft.lb).

NOTE: Use bolt 40 mm (1.57 in) in length.

(d) Install two new gaskets and No.2 EGR pipe with the two bolts and two nuts, tighten to 22.5 Nm (230 kg.cm, 17 ft.lb).

NOTE: Use bolt 20 mm (0.79 in) in length.

(e) Connect the heater hose to the water bypass pipe.

(f) Connect these hoses:
- Brake booster vacuum hose (1) to union on air intake chamber.
- PCV hose to PCV valve (2) on LH cylinder head.
- Water bypass hose from EGR valve (3) to rear water bypass joint.
- Water bypass hose from throttle body (4) to rear water bypass joint.
- Vacuum hose from VSV for fuel pressure control (5) to fuel pressure regulator.
- EVAP hose from charcoal canister (6) to VSV for EVAP
(g) Connect these connectors:
- Throttle position sensor connector with Traction Control System (TRAC).
- Sub-throttle position sensor connector w/ TRAC.
- Sub-throttle actuator connector IAC valve connector.
- EGR valve connector.
- EGR gas temperature sensor connector.
- VSV connector for fuel pressure control.
- VSV connector for EVAP.
(h) Install the accelerator bracket with the two bolts.
(i) Connect these cables:
- Accelerator cable.
- A/T throttle control cable.
- Cruise control actuator cable.
6. Install timing belt rear plates tighten to 7.5 in m (80 kg.cm, 66 inch lbs.).

7. Install the No.2 ignition coil with the two bolts, then connect the ignition coil connector.
8. Install high-tension (spark plug wires) cords, cord clamps and cord cover assembly as follows:

(a) Connect the high-tension cords to the spark plugs, distributor caps and No.2 ignition coil.
(b) Install the lower high-tension cord cover with the stud bolt.
(c) Connect the RH front high-tension cord clamp to the lower high-tension cord cover.
(d) Place the RH front high-tension cord clamp to the RH rear high-tension cord clamp.
(e) Install the two bolts holding the RH high-tension cord clamps to the RH cylinder head cover.
(f) Connect the No.2 high-tension cord to the cord clamp on the RH front high-tension cord clamp.

(g) Connect the LH front high-tension cord clamp to the lower high-tension cord cover.
(h) Place the LH front high-tension cord clamp to the LH rear high-tension cord clamp.
(i) Install the two bolts holding the LH high-tension cord clamps to the LH cylinder head cover.
(j) Connect the No.1 high-tension cord to the cord clamp on the LH front high-tension cord clamp.

9. Install a new gasket and the front TWC with three new nuts tighten to 61.8 Nm (630 kg.cm, 46 ft.lb).
10. Connect front exhaust pipe to front TWC as follows:

(a) Install the pipe support bracket to the transmission with the two bolts hand tight.
(b) Install a new gasket to each front end of the front exhaust pipe.
(c) Connect the front exhaust pipe to the two front TWC with the four bolts and four new nuts, tighten to 44 Nm (440 kg.cm, 32 ft.lb).
(d) Tighten the two bolts holding the pipe support bracket to the transmission to 44 Nm (440 kg.cm, 32 ft.lb).
11. Install the Power Steering (PS) pump with the three bolts and the nut, then alternately tighten bolts to 39 Nm (400 kg.cm, 29 ft. lbs) and the nut to 43 Nm (440 kg.cm, 32 ft.lb).
12. Connect the PS air hose to the air intake chamber.

TIMING BELT INSTALLATION
1. Install camshaft timing pulleys.
2. Connect timing belt to camshaft timing pulleys.
3. Check engine oil level.