Installation

CYLINDER HEAD

INSTALLATION

1. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH
a. Place a new gasket on the cylinder head with the white mark facing the manifold side.

NOTICE: Be careful of the installation direction.

b. Install the exhaust manifold with 8 new nuts. Uniformly tighten the nuts in several passes.
Torque: 44 Nm (449 kgf-cm, 32 ft. lbs.)

2. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2
a. Install the heat insulator with the 4 bolts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)

3. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
a. Place a new gasket on the cylinder head with the white mark facing the manifold side.

NOTICE: Be careful of the installation direction.

b. Install the exhaust manifold with 8 new nuts. Uniformly tighten the nuts in several passes.
Torque: 44 Nm (449 kgf-cm, 32 ft. lbs.)

4. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1
a. Install the heat insulator with the 4 bolts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)

LH Bank:

5. INSTALL NO.2 CYLINDER HEAD GASKET
a. Place a new cylinder head gasket in position on the cylinder block.

HINT: The rear side of the cylinder head gasket has marks so that the RH and LH banks can be distinguished. A 3L mark is on the LH bank's gasket.

NOTICE: Be careful of the installation direction.

6. INSTALL CYLINDER HEAD LH
a. Check that the timing mark of the crankshaft timing pulley is in the position shown in the illustration, and that the piston is below the TDC of compression.
b. Install the cylinder head together with the exhaust manifold to the cylinder block.
c. Apply a light coat of engine oil on the threads and under the head of the cylinder head bolts.
d. Put the washer on the bolt, and insert the bolt with washer into the cylinder head.

NOTICE: Be careful not to drop washers into the cylinder head.

LH Bank:

e. Install and uniformly tighten the 10 cylinder head bolts and plate washers in the sequence shown in the illustration.
Torque: 59 Nm (601 kgf-cm, 44 ft. lbs.)

f. Mark the front of the cylinder head bolt's head with paint.
g. Retighten the cylinder head bolts by 90° in the sequence shown in the illustration.
h. Check that the painted mark is now at a 90° angle to the front.

RH Bank:

7. INSTALL CYLINDER HEAD GASKET
a. Place a new cylinder head gasket in position on the cylinder block.

HINT: The rear side of the cylinder head gasket has marks so that the RH and LH banks can be distinguished. A 3R mark is on the RH bank's gasket.

NOTICE: Be careful of the installation direction.

8. INSTALL CYLINDER HEAD SUB-ASSEMBLY
a. Check that the timing mark of the crankshaft timing pulley is in the position shown in the illustration, and that the piston is below the TDC of compression.
b. Install the cylinder head together with the exhaust manifold to the cylinder block.
c. Apply a light coat of engine oil on the threads and under the head of the cylinder head bolts.
d. Put the washer on the bolt, and insert the bolt with washer into the cylinder head.

NOTICE: Be careful not to drop washers into the cylinder head.

RH Bank:

e. Install and uniformly tighten the 10 cylinder head bolts, and plate washers in the sequence shown in the illustration.
Torque: 59 Nm (601 kgf-cm, 44 ft. lbs.)

10. INSTALL FRONT WATER BY-PASS JOINT
A. Install 2 new gaskets and the water by-pass joint with the 4 nuts. Alternately tighten the nuts.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)
b. Connect the ECT connector.

11. INSTALL WATER INLET HOUSING
a. Install a new O-ring to the water inlet housing.
b. Apply soapy water on the O-ring.
c. Apply seal packing to the sealing groove of the inlet housing as shown in the illustration. Seal packing:
Part No.08826-00100 or equivalent
Seal width: 2 to 3 mm (0.08 to 0.12 inch)

NOTICE:
^ Remove any oil from the contact surface.
^ Install the water inlet housing within 3 minutes after applying seal packing.
^ Do not start the engine for at least 2 hours after installing.

d. Install the water inlet and housing with the 2 bolts. Alternately tighten the bolts.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)

12. INSTALL REAR WATER BY-PASS JOINT
a. Install 2 new gaskets and the water by-pass joint with the 4 nuts. Alternately tighten the nuts.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)

13. INSTALL INTAKE MANIFOLD ASSEMBLY
a. Installation procedure.

14. INSTALL NO.2 FUEL PIPE SUB-ASSEMBLY
15. INSTALL NO.3 CAMSHAFT SUB-ASSEMBLY

NOTICE: 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.

a. Apply engine oil to the cam and gear of the camshaft and also the journal of the cylinder head.
b. Align the timing marks (2 dot marks each) of the camshaft drive and driven main gears, and place the No.3 and No.4 camshafts.
c. Set the timing mark (2 dot marks each) of the camshaft drive and driven main gears at an angle of approximately 10°.

d. Apply seal packing to the camshaft housing plug.
^ Remove the old packing (FIPG) material.
^ Apply seal packing to the housing plug as shown in the illustration.
Seal packing: Part No.08826-00080 or equivalent

e. Install the camshaft housing plug to the cylinder head as shown in the illustration.
f. Install the oil control valve filter to the cylinder head.

NOTICE: Be careful of the installation direction.

g. Apply seal packing to the front bearing cap.
^ Remove any old packing (FIPG) material.
^ Apply seal packing to the bearing cap as shown in the illustration.
Seal packing: Part No.08826-00080 or equivalent
Seal width: 1.5 to 2.0 mm (0.059 to 0.079 inch)

NOTICE: Do not apply seal packing to the front bearing cap grooves.

h. Install the front bearing cap.

HINT: Installing the front bearing cap will determine the thrust portion of the camshaft.

i. Install the other bearing caps in the sequence shown with the arrow mark facing forward.

j. Push in the camshaft oil seal.

k. Install 4 new seal washers to the bearing cap bolts (1 to 4).
l. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts (5 to 22).

NOTICE:
Do not apply engine oil under the heads of the bearing cap bolts (1 to 4).

m. Install the oil feed pipe and the 22 bearing cap bolts.
n. Uniformly tighten the 22 bearing cap bolts in several passes in the sequence shown in the illustration.
Torque: 7.5 Nm (76 kgf-cm, 66 ft. lbs.) for bolts 21 and 22 16 Nm (163 kgf-cm, 12 inch lbs.) for other bolts
o. Remove the service bolt.

16. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

17. INSTALL CAMSHAFT TIMING PULLEY SUB-ASSEMBLY LH
a. Align the camshaft timing tube knock pin with the knock pin groove of the timing pulley.
b. Attach the timing pulley to the camshaft timing tube. Face the timing pulley's "L" mark forward.
c. Hold the camshaft with a wrench and install the 4 pulley bolts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)

18. INSTALL CAMSHAFT

NOTICE: 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.

a. Apply engine oil to the cam and gear of the camshaft and also the journal of the cylinder head.
b. Align the timing marks (1 dot mark each) of the camshaft drive and driven main gears, and place the intake and exhaust camshafts.
c. Set the timing mark (1 dot mark each) of the camshaft drive and driven main gears at an angle of approximately 100.

j. Push in the camshaft oil seal.

o. Remove the service bolt.

19. INSTALL INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

20. INSTALL CAMSHAFT TIMING PULLEY SUB-ASSEMBLY RH
a. Align the camshaft timing tube knock pin with the knock pin groove of the timing pulley.
b. Attach the timing pulley to the camshaft timing tube. Face the timing pulley's R mark forward.
c. Hold the camshaft with a wrench and install the 4 pulley bolts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)

21. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH
a. Remove any old packing (FIPG) material.
b. Apply seal packing to the cylinder heads as shown in the illustration.
Seal packing: Part No.08826-00080 or equivalent

NOTICE:
^ Remove any oil from the contact surface.
^ Install the oil pan within 5 minutes after applying seal packing.
^ Do not start the engine within 2 hours after installing.

c. Install the gasket to the cylinder head cover.
d. Install the seal washer to the bolt.
e. Install the cylinder head cover with the 9 bolts. Uniformly tighten the bolts in several passes.
Torque: 6.0 Nm (61 kgf-cm, 53 inch lbs.)
f. Install the wire clamp bracket on the engine wire to the cylinder head.
g. Install the wire clamp bracket on the engine wire to the camshaft bearing cap.

22. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
a. Remove any old packing (FIPG) material.
b. Apply seal packing to the cylinder heads as shown in the illustration.
Seal packing: Part No.08826-00080 or equivalent

NOTICE:
^ Remove any oil from the contact surface.
^ Install the oil pan within 5 minutes after applying seal packing.
^ Do not start the engine within 2 hours after installing.

c. Install the gasket to the cylinder head cover.
d. Install the seal washer to the bolt.
e. Install the cylinder head cover with the 9 bolts. Uniformly tighten the bolts in several passes.
Torque: 6.0 Nm (61 kgf-cm, 53 inch lbs.)
f. Install the wire clamp bracket on the engine wire to the cylinder head.
g. Install the wire clamp bracket on the engine wire to the camshaft bearing cap.

23. INSTALL IGNITION COIL
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)

24. INSTALL TIMING BELT
a. Install the timing belt.

25. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
26. PERFORM INITIALIZATION
a. Perform initialization.

NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.