Removal and Installation

Note: When installing sliding parts such as rocker arms and camshaft, be sure to apply engine oil on the sliding surfaces. When installing welch plug, apply sealant.

Removal
1. Set No. 1 cylinder at T.D.C. on its compression stroke. Then remove timing belt.

Caution: After removing timing belt, do not rotate crankshaft and camshaft separately, because valves will hit piston heads.





2. Remove rocker shafts with rocker arms and securing bolts. The bolts should be loosened in two or three stages.





3. Remove camshaft sprocket.





4. Disconnect exhaust tube from exhaust manifold. Remove cylinder head together with manifolds.

Caution: Bolts should be loosened in two or three stages. Head warpage or cracking could result from removing in incorrect order.

5. Remove manifolds from cylinder head.





INSTALLATION
1. Install cylinder head with new gasket.
^ Be sure to install washers between bolts and cylinder head.

Caution: Do not rotate crankshaft and camshaft separately, because valves will hit piston heads.





2. Apply oil to the thread portion and seat surface of bolts and tighten cylinder head bolts with washers.
Tightening procedure.
1st Tighten all bolts to 29 N-m (3.0 kg-m, 22 ft-lb).
2nd Tighten all bolts to 78 N.m (8.0 kg-m, 58 ft-lb).
3rd Loosen all bolts completely.
4th Tighten all bolts to 29 N-m (3.0 kg-m, 22 ft-lb).
5th Tighten all bolts to 74 to 83 N.m (7.5 to 8.5 kg-m, 54 to 61 ft-lb) or if you have an angle wrench, turn bolt (8) 83 to 88 degrees and the other bolts 75 to 80 degrees clockwise.





3. Install camshaft sprocket.
Tighten Camshaft sprocket:
78 - 88 N-m (8.0 - 9.0 kg-m, 58 - 65 ft-lb)





4. Confirm that No.1 cylinder is set at T.D.C. on its compression stroke as follows:
(1) Set crankshaft key near to the top.





(2) Check camshaft sprocket aligning mark at the top.





5. Install timing belt and adjust belt tension. Refer to Timing Belt.





6. Install rocker shaft with rocker arms.





7. Tighten rocker shaft bolts.

Tighten bolts gradually, in two or three stages, outwardly from center position.
Rocker shaft bolts:
18 - 22 N.m (1.8 - 2.2 kg-m, 13 - 16 ft-lb)





8. Install distributor.
(1) Set No. 1 cylinder at T.D.C. on its compression stroke.
(2) Install distributor in cylinder head.





(3) Make sure that a letter marked on distributor cap is placed on upper side.





9. Install intake and exhaust manifolds.
Tighten Intake manifold:
20 - 25 N.m (2.0 - 2.6 kg-m, 14 - 19 ft-lb)
Tighten Exhaust manifold:
20 29 N.m (2.0 - 3.0 kg-m, 14 - 22 ft-lb)





10. Push forcefully on the top face of hydraulic lash adjuster with finger. If hydraulic lash adjuster moves 1 mm (0.04 in) or more, air may be mixed into it. If so, draw air from hydraulic lash adjuster as follows.
^ Install rocker cover.
^ Run engine at approximately 1,000 rpm under no-load for about 10 minutes.
^ Remove rocker cover again and push the top face of hydraulic lash adjuster.
^ If hydraulic lash adjuster still moves 1 mm (0.04 in) or more, replace hydraulic lash adjuster. (Refer to Step 11.)

11. Replacement of hydraulic lash adjuster.
1) Remove timing belt.
2) Remove rocker shafts with rocker arms and securing bolts.
3) Remove cylinder stopper at the malfunctional hydraulic lash adjuster.

Note: Pay attention not to bend cylinder stopper when removing it.





4) Draw the malfunctional lash adjuster and then replace with new one.
5) Reinstall timing belt and adjust belt tension. (Refer to Timing Belt.)
6) Reinstall rocker shaft with rocker arms.
7) Reinstall rocker cover.