Removal and Installation

Components

Removal
1. Release the fuel pressure.
2. Remove the timing belt.








3. Drain the engine coolant by removing the drain plugs from both sides of the cylinder block as shown.
4. Separate the ASCD and the accelerator control wires from the intake manifold collector (VG33E only).
5. Remove the intake manifold collector from the engine (VG33E only).





6. Disconnect the following parts:
a. Harness connectors for:
^ IACV-AAC valve
^ Throttle position sensor
^ Throttle position switch
^ Distributor (ignition coil)
^ Distributor
^ EGRC solenoid valve (VG33E only)
^ EGR temperature sensor (VG33E only)
b. Water hoses from the intake manifold collector (VG33ER only)
c. Heater hoses
d. PCV hose from the rocker cover
e. Vacuum hoses for:
^ EVAP canister
^ Brake master cylinder
^ Pressure regulator
f. Purge hose from the purge control valve
g. Spark plug wires
h. Three left or right bank fuel injector connectors
i. Ground harness
j. EGR tube (VG33E only)





7. Remove the fuel feed and fuel return hoses from the fuel injector tube assembly.
8. Remove the fuel injector tube assembly.

Intake Manifold Disassembly Sequence:

9. Remove the intake manifold from the engine. The following parts should be disconnected to remove the intake manifold.
^ Engine coolant temperature switch harness connector
^ Thermal transmitter harness connector
^ Water hose from thermostat housing





10. Remove both of the camshaft sprockets.
11. Remove the rear timing belt cover.
12. Remove the distributor and ignition wires.

CAUTION: After pulling out the distributor from the cylinder head, do not rotate the distributor rotor.

13. Remove harness clamp from RH rocker cover.
14. Remove exhaust tube from exhaust manifold.
15. Remove the A/C compressor.
16. Remove the generator.
17. Remove the power steering pump.





18. Remove the A/C compressor, generator, and power steering pump brackets.

Rocker Arm Cover Disassembly Sequence:

19. Loosen and remove the bolts from both rocker covers in the numerical order as shown. Remove both of the rocker covers.





20. Remove the cylinder head with the exhaust manifold attached.
^ Remove the cylinder head bolts in the specified numerical order or a warped or cracked cylinder head could result from removing the bolts in the incorrect numerical order.
^ Cylinder head bolts should be loosened in two or three steps in the numerical order as shown.

Installation





1. Set the No. 1 piston at TDC on the compression stroke as follows:
a. Align the crankshaft sprocket alignment mark with the mark on the oil pump housing as shown.
b. Confirm that the knock pin on the camshaft is still set at the top.








2. Install both of the engine block drain plugs and tighten to specification.
Engine block drain plugs : 34 - 44 Nm (3.5 - 4.5 kgf-cm, 25- 33 ft. lbs.)
^ Use Genuine High Performance Thread Sealant or equivalent.

Exhaust Manifold Assembly Sequence:

3. Install the exhaust manifold on to the cylinder head.

CAUTION: Tighten the exhaust manifold bolts to specification in the numerical order as shown.





4. Install cylinder head with new gasket.
^ Install the washers between the bolts and cylinder head with the washer beveled side up as shown.
^ Do not rotate the crankshaft and camshaft separately, or the valves will hit the pistons.








5. Tighten the cylinder head bolts and the intake manifold bolts in 14 steps, and in the numerical order as shown. Use the specified angle wrench as necessary.
Angle wrench : ST10120000 (J24239-01)
^ Apply engine oil to the threads and seating surfaces of the cylinder head bolts before installation.
^ Cylinder head bolts No. 4, 7, 9, and 12 (L1) are longer than the others (L2).
Cylinder head bolts "L" : 127 mm (5.00 inch)
Cylinder head bolts "Lo : 106 mm (4.17 inch)
^ Install the intake manifold and the cylinder head at the same time using the 14 steps.





Cylinder head and intake manifold nuts and bolts tightening:
Step 1 : tighten cylinder head bolts 29 Nm (3.0 kgf-cm, 22 ft. lbs.)
Step 2 : tighten cylinder head bolts 59 Nm (6.0 kgf-cm, 43 ft. lbs.)
Step 3 : loosen all cylinder head bolts completely
Step 4 : tighten cylinder head bolts 10 Nm (1.0 kgf-cm, 7 ft. lbs.)
Step 5 : tighten intake manifold bolts and nuts 4 Nm (0.4 kgf-cm, 2.9 ft. lbs.)
Step 6 : tighten intake manifold bolts and nuts 18 Nm (1.8 kgf-cm, 13 ft. lbs.)
Step 7 : tighten intake manifold bolts and nuts 16 - 20 Nm (1.6 - 2.0 kgf-cm, 12 -14 ft. lbs.)
Step 8 : loosen all intake manifold bolts and nuts completely
Step 9 : tighten cylinder head bolts to 29 Nm (3.0 kg-m, 22 ft. lbs.)
Step10 : tighten cylinder head bolts 60° - 65° degrees (clockwise), if an angle wrench is not available, tighten cylinder head bolts 54 - 64 Nm (5.5 - 6.5 kgf-cm, 40 - 47 ft. lbs.)
Step 11: tighten cylinder head sub-bolts to 9.0 -11.8 Nm (0.92 -1.20 kgf-cm, 6.7 - 8.7 ft. lbs.)
Step 12: tighten intake manifold bolts and nuts to 4 Nm (0.4 kgf-cm, 2.9 ft. lbs.)
Step 13: tighten intake manifold bolts and nuts to 9 Nm (0.9 kgf-cm, 6.5 ft. lbs.)
Step 14: tighten intake manifold bolts and nuts to 8 - 10 Nm (0.8 -1.0 kgf-cm, 5.8 - 7 ft. lbs.)

Intake Manifold Assembly Sequence:

^ If only the intake manifold is removed, install the manifold using three steps and tightening the manifold nuts and bolts to specification:
Intake manifold nuts and bolts tightening steps:
Step 1 : 4 Nm (0.4 kgf-cm, 2.9 ft. lbs.)
Step 2 : 9 Nm (0.9 kgf-cm, 6.5 ft. lbs.)
Step 3 : 8 - 10 Nm (0.8 - 1.0 kgf-cm, 5.8 - 7 ft. lbs.)

CAUTION: If replacing the intake manifold with a new one, the cylinder head gasket must also be replaced with a new one.

Rocker Arm Cover Assembly Sequence:

6. Install the rocker covers and tighten the bolts to specification.
Rocker cover bolts : 1 - 3 Nm (0.1 - 0.3 kgf-cm, 9 - 26 inch lbs.)





7. Install the A/C compressor, generator, and power steering pump brackets.
8. Install the power steering pump.
9. Install the A/C compressor.
10. Install the generator.
11. Install the exhaust front tube to the exhaust manifold.

Fig. 9 Camshaft Pulley Identification:

12. Install the rear timing belt cover and camshaft sprocket as shown.

CAUTION: RH camshaft sprocket and LH camshaft sprocket are different parts. Be sure to install them in the correct location.

13. Install the timing belt and adjust the timing belt tension.
14. Install the distributor.





a. Align the mark on the distributor shaft with the protruding mark on the distributor housing as shown.





b. After installing, confirm that distributor rotor head is set as shown in figure.





15. Install the fuel injector tube assembly.
16. Connect the fuel injector harness connectors.
17. Install the fuel feed and fuel return hoses to the fuel injector tube assembly.
18. Install the intake manifold collector (VG33E only).





19. Connect the following parts:
a. Harness connectors for:
^ IACV-AAC valve
^ Throttle position sensor
^ Throttle position switch
^ Distributor (ignition coil)
^ Distributor
^ EGRC solenoid valve (VG33E only)
^ EGR temperature sensor (VG33E only)
b. Water hoses from the intake manifold collector (VG33ER only)
c. Heater hoses
d. PCV hose from the rocker cover
e. Vacuum hoses for:
^ EVAP canister
^ Brake master cylinder
^ Pressure regulator
f. Purge hose from the purge control valve
g. Spark plug wires.
h. Three left/right bank fuel injector connectors
i. Ground harness
j. EGR tube (VG33E only)
20. Install the ASCD and accelerator control wires on to the intake manifold collector (VG33E only).





21. Check the hydraulic valve lifter.
a. Push the plunger forcefully with your finger. Be sure to check the lifter with the rocker arm is in the free position (not on the camshaft lobe).
b. If the valve lifter moves more than 1 mm (0.04 inch), air may be trapped inside.
c. Bleed off the air by running the engine at 1,000 rpm under no load for about 10 minutes.
d. If the hydraulic lifters are still noisy, replace the lifters.
e. Bleed off the air by running the engine at 1,000 rpm under no load for about 10 minutes. Repeat as necessary to bleed the air out of the new lifters.
22. Install the remaining components in the reverse order of removal.