Installation

CYLINDER HEAD

COMPONENTS:

INSTALLATION

1. INSTALL CYLINDER HEAD GASKET
a) Place a new cylinder head gasket on the cylinder block with the Lot No. stamp facing upward.

NOTICE:
^ Remove any oil from the contact surface.
^ Be careful of the mounting orientation.
^ Place the cylinder head on the gasket gently so as not to damage the gasket at the bottom part of the head.

2. INSTALL CYLINDER HEAD

HINT: The cylinder head bolts are tightened in 2 successive steps.

a) Apply seal packing as shown in the illustration.
Seal packing: Part No. 08826-00100
Standard seal diameter: 4.5 to 5.5 mm (0.177 to 0.217 inch)

NOTICE:
^ Remove any oil from the contact surface.
^ Install the cylinder head within 3 minutes of applying seal packing.

b) Apply a light coat of engine oil to the threads of the cylinder head bolts.

c) Using several steps, install and tighten the 10 cylinder head bolts and plate washers uniformly with an 8 mm bi-hexagon wrench in the sequence shown in the illustration.
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)

d) Mark the front of the cylinder head bolt with paint.
e) Retighten the cylinder head bolts by an additional 90° and then another additional 90°, as shown in the illustration.
f) Check that the paint mark is now 180° opposite to the front.

3. INSTALL CAMSHAFT TIMING GEAR
a) Put the camshaft timing gear assembly and the camshaft together with the straight pin off the groove, as shown in the illustration.
b) Turn the camshaft timing gear assembly clockwise while pushing it lightly towards the camshaft. Push further at the position where the pin fits into the groove.

NOTICE: Be careful not to turn the camshaft timing gear to the retard angle (to the right).

c) Check that there is no clearance between the gear fringe and camshaft.
d) Tighten the flange bolt with the camshaft timing gear fixed.
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
e) Check that the camshaft timing gear assembly can move to the retard angle (to the right) and is locked in the most retarded position.

4. INSTALL CAMSHAFT TIMING SPROCKET
a) Clamp the camshaft in a vise.
b) Align the knock pin hole of the camshaft timing sprocket with the knock pin of the camshaft, and install the camshaft timing sprocket.
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)

NOTICE: Be careful not to damage the camshaft.

5. INSTALL CAMSHAFT
a) Apply a light coat of engine oil to the camshaft journals.
b) Place the camshaft on the cylinder head with the timing mark on the camshaft timing gear facing upward.
c) Examine the front marks and numbers, and tighten the bolts in the sequence shown in the illustration.
Torque: 13 Nm (129 kgf-cm, 9 ft. lbs.)

NOTICE: Tighten each bolt uniformly, keeping the camshaft level.

d) Install the No. 1 bearing cap.
Torque: 23 Nm (235 kgf-cm, 17 ft. lbs.)

6. INSTALL FUEL INJECTOR
7. INSTALL FUEL DELIVERY PIPE
8. INSTALL CHAIN
9. INSTALL OIL PUMP SEAL
10. INSTALL TIMING CHAIN COVER
11. INSTALL WATER PUMP
12. INSTALL ENGINE MOUNTING BRACKET RH
13. INSTALL ENGINE MOUNTING INSULATOR RH
14. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
15. INSTALL CRANKSHAFT POSITION SENSOR
16. INSTALL WATER PUMP PULLEY
17. INSTALL CRANKSHAFT PULLEY
18. INSTALL CYLINDER HEAD COVER
19. INSTALL IGNITION COIL
20. INSTALL NO. 2 CYLINDER HEAD COVER
21. INSTALL GENERATOR
22. INSTALL VANE PUMP V BELT
23. INSTALL GENERATOR V BELT
24. ADJUST GENERATOR V BELT
25. ADJUST VANE PUMP V BELT
26. INSPECT DRIVE BELT DEFLECTION AND TENSION
27. INSTALL CAMSHAFT TIMING CONTROL VALVE ASSEMBLY
28. CONNECT NO. 2 VENTILATION HOSE
29. CONNECT VENTILATION HOSE
30. INSTALL IGNITION COIL
31. INSTALL OIL DIPSTICK GUIDE
a) Apply engine oil to a new O-ring and install it to the dipstick guide.
b) Install the dipstick guide with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)

32. INSTALL INTAKE MANIFOLD
a) Install a new gasket onto the intake manifold.
b) Install the intake manifold with the 3 bolts and 2 nuts. Using several steps, uniformly tighten the bolts and nuts in the sequence shown in the illustration.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)

33. INSTALL EXHAUST MANIFOLD

34. INSTALL MANIFOLD SUPPORT BRACKET
a) Install the manifold support bracket with the 3 bolts.
Torque: 44 Nm (449 kgf-cm, 32 ft. lbs.)

35. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
a) Install the No. 1 exhaust manifold heat insulator with the 4 bolts.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)

36. INSTALL FRONT EXHAUST PIPE
a) Place a new gasket on the exhaust manifold.
b) Install the 2 compression springs and 2 bolts.
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.)

37. INSTALL WATER FILLER
a) Install the water filler with the 2 bolts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
b) Connect the radiator reservoir tank hose.
c) Connect the No. 3 radiator hose.
d) Connect the radiator inlet hose.
38. INSTALL NO. 1 WATER BY-PASS PIPE
a) Install the water by-pass pipe with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)

39. CONNECT RADIATOR HOSE INLET
a) Connect the radiator hose inlet to the union.

40. CONNECT UNION TO CHECK VALVE HOSE
a) Connect the union to check valve hose to the brake booster.
41. CONNECT FUEL TUBE
42. INSTALL ACCELERATOR CONTROL CABLE
43. CONNECT ENGINE WIRE
44. INSTALL AIR CLEANER
45. INSTALL OIL PAN DRAIN PLUG
46. ADD ENGINE OIL
47. CHECK FOR ENGINE OIL LEAKS
48. ADD COOLANT
49. CHECK FOR ENGINE COOLANT LEAKS
50. CHECK FOR FUEL LEAKS
51. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL