Installation

1. Install a new cylinder head gasket and then the cylinder head. Install cylinder head bolts.

NOTE:
- The cylinder head bolts are tightened in 2 passes, steps (c) through (f)).
- If any of bolts break or deform, replace them.
- If any of the bolts do not meet the torque specification, replace the bolt.

(a) Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
(b) Install the 14 plate washers to each cylinder head bolt.





(c) Using a 10 mm bi-hexagon wrench, uniformly tighten the cylinder head bolts, in several passes, in the sequence shown to 34 Nm (25 ft. lbs.).





(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) Retighten cylinder head bolts by an additional 90° shown.
(g) Check that the painted mark is now turned to the rear.


2. Install camshafts.
(a) Apply engine oil to the thrust portion of the camshaft.





(b) Place the camshaft on the cylinder head with the cam lobe facing up as shown.





(c) Place the No. 3 and No. 7 bearing caps in their proper location.
(d) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.





(e) Temporarily tighten these bearing cap bolts uniformly and alternately, in several passes, until the bearing caps are snug with the cylinder head.





(f) Apply MP grease to a new camshaft oil seal lip.
(g) Install the 2 oil seals to the camshafts.
(h) Clean the installed surfaces of the No. 1 bearing cap and cylinder head with cleaner.





(i) Apply seal packing Part No. 08826 - 00080, or equivalent, to the No. 1 bearing cap as shown.





(j) Install the No. 1, No. 2, No. 4, No. 5 and No. 6 bearing caps in their proper locations.
(k) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.





(l) Install and uniformly tighten the 14 bearing cap bolts on one side, in several passes, in the sequence shown to 20 Nm (14 ft. lbs.).





(m) Using SST 09316 - 60011 (09316 - 00011, 09316 - 00051), push the 2 oil seals in as far as they can go.
(n) Rotate the camshaft with a wrench at the hexagon position, bring the forward straight pin up.





(o) Loosen the 12 bearing cap bolts as shown, until they can be turned by hand; retighten, in several passes to 20 Nm (14 ft. lbs.).





(p) Turn the camshaft 1/3 of revolution.
(q) Loosen the 8 bearing cap bolts as shown, until they can be turned by hand; retighten, in several passes to 20 Nm (14 ft. lbs.).





(r) Turn the camshaft a further 1/3 of a revolution.
(s) Loosen the 8 bearing cap bolts as shown, until they can be turned by hand; retighten, in several passes to 20 Nm (14 ft. lbs.).
3. Turn the camshaft, and position the cam lobe upward, check and adjust the valve clearance.





4. Install No. 4 timing belt cover with the 4 bolts and torque to 8.8 Nm (78 inch lbs.).





5. Install camshaft timing pulleys.
(a) Align the camshaft knock pin with the groove in the pulley, and slide on the pulley.
(b) Temporarily install the timing pulley bolt.





(c) Hold the hexagon portion of the camshaft with a wrench, and tighten the timing pulley bolt to 79 Nm (59 ft. lbs.).
6. Install No. 1, No. 2 and No. 3 cylinder head covers.
(a) Remove any old packing (FIPG) material.





(b) Apply seal packing Part No. 08826 - 00080, or equivalent, to the cylinder head as shown it the illustration.
(c) Install the gaskets to the No. 1 and No. 2 cylinder head covers.
(d) Install the No. 1 cylinder head cover with the 4 bolts and torque to 8.3 Nm (74 inch lbs.).
(e) Install the No. 2 cylinder head cover with the 4 bolts and torque to 8.3 Nm (74 inch lbs.).
(f) Install the No. 3 cylinder head cover with the 4 bolts and 4 nuts and torque to 8.3 Nm (74 inch lbs.).
(g) Install the PCV valve.
7. Install a new gasket, the intake manifold and delivery pipe assembly with the 6 bolts and 2 nuts and torque to 27 Nm (20 ft. lbs.)
8. Install fuel inlet pipe.
(a) Connect the fuel inlet pipe with 2 new gaskets and the union bolt and torque to 42 Nm (30 ft. lbs.).
(b) Install the clamp bolt to the intake manifold.
9. Install fuel pressure pulsation damper. Refer to Powertrain Management.
10. Install intake manifold stay and torque to 39 Nm (29 ft. lbs.).
11. Install water outlet with water bypass hose and torque to 21 Nm (15 ft. lbs.).
12. Connect the engine wire.
(a) Install the engine wire protector to the intake manifold with the 3 nuts.
(b) Connect these connectors:
- ECT sensor connector.
- ECT sander gauge connector.
- 2 knock sensor connectors.
- Oil pressure switch connector.
- Oil level sensor connector.
- A/C compressor connector 6 injector connectors.

NOTE: The No. 1, No. 3 and No. 5 injector connectors are dark gray, and the No. 2, No. 4 and No. 6 injector connectors are gray.

(c) Install the wire clamp to the fuel return pipe.
(d) Install the 2 ground straps to the intake manifold with the bolts.
(e) Connect these connectors:
- Heated oxygen sensor (bank 1 sensor 1) connector.
- Crankshaft position sensor connector.
(f) Connect the wire clamp to the bracket.
13. Install timing belt.
14. Install spark plugs.
15. Install distributor and high-tension cords assembly.
16. Connect high-tension cords to spark plugs and ignition coil.
17. install No. 3 timing belt cover.
18. Install cylinder head rear cover.
19. Install air intake chamber.
(a) Install a new gasket and the intake chamber with the 5 bolts and nut and torque to 27 Nm (20 ft. lbs.)
(b) Install the bolt holding the engine wire protector to the air intake chamber.
(c) Connect these hoses:
- Vacuum hose to brake booster union.
- EVAP hose to No. 2 vacuum pipe.
20. Install DLC1 bracket and VSV assembly.
21. Install vacuum control valve set and torque to 21 Nm (15 ft. lbs.).
22. Install No. 2 vacuum pipe and VSV assembly and torque to 27 Nm (20 ft. lbs.).
23. Connect EGR gas temperature sensor connector.
24. Install oil dipsticks and guides for engine and transmission.
(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) oil pan.
(d) Install the dipstick guide with the bolt.
(e) Install the dipstick.
25. Install air intake chamber stays.

NOTE: The No. 1 stay is marked with "F", and No. 2 stay is marked with "R".

(a) Install the No. 1 stay with the bolt and nut and torque to 18 Nm (13 ft. lbs.).
(b) Install the No. 2 stay with the bolt and nut and torque to 18 Nm (13 ft. lbs.).
26. Install throttle body and intake air connector assembly.
27. Install engine wire bracket.
28. Connect fuel return hose.
29. Install PS pump.
(a) Install the pump rear stay with the 2 bolts and torque to 39 Nm (29 ft. lbs.).
(b) Install the vane pump with the 2 bolts and torque to 58 Nm (43 ft. lbs.).
(c) Connect these hoses:
- PS air hose to No. 4 timing belt cover
- PS air hose to air intake chamber
30. Install No. 1 water bypass pipe and water bypass outlet.
31. Install exhaust manifolds.
(a) Install a new gasket and the exhaust manifold with 4 the nuts. Install the No. 1 and No. 2 exhaust manifolds and torque to 39 Nm (29 ft. lbs.).
(b) Connect the 2 heated oxygen sensor connectors.
32. Install No. 2 front exhaust pipe.
33. Install water pump pulley, fan, fluid coupling assembly and drive belt.
34. Install air cleaner, map meter and intake air connector pipe assembly.
35. Connect control cables to throttle body
36. Fill with engine coolant
37. Start engine and check for leaks
38. Check ignition timing
39. Install engine under cover
40. Road test and check for abnormal noise, shock, slippage, correct shift points and smooth operation.
41. Check engine coolant level.