Cylinder Head Installation

1. Make sure the block and head surfaces are completely clean and free of any debris.






2. Place the new head gasket in position on the block. Make sure the installation direction is correct.
3. Place the head in position on the head gasket.
4. Apply a light coat of engine oil on the threads and under the heads of the head bolts.

Cylinder Head Installation Torque Sequence:

5. Using SST #09043-88010 or equivalent, uniformly tighten the ten head bolts in several passes in the sequence shown. Final torque should be 64 N.m (47 ft.lbs).
6. Camshafts MUST be installed level so as not to damage the cylinder head. Follow the procedure very carefully.
7. Apply MP grease to the thrust portion of the cam.






8. Place the intake cam at 80° BTDC of cam angle on the cylinder head as shown.






9. Apply seal packing, to the No.1 bearing cap as shown.






10. Install the bearing caps in their proper locations as shown.
11. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.

Intake Camshaft Bearing Cap Tightening Sequence:

12. Install and uniformly tighten the ten bearing cap bolts in several passes in the sequence shown. Final torque should be 19 N.m (14 ft.lbs).






13. Apply MP grease to the new oil seal lip.






14. Using SST # 09223-46011 or equivalent, carefully tape the oil seal in.






15. Set the knock pin of the intake cam at 10° BTDC of cam angle as shown.
16. Apply MP grease to the thrust portion of the cam.






17. Engage the exhaust cam gear to the intake cam gear by matching the timing marks on each gear as shown above.
18. Roll down the exhaust cam onto the bearing journals while engaging gears to each other.

Caution: Do NOT use the assembly reference marks as noted in the image.

19. Carefully rock the intake cam back and forth (clockwise/counter clockwise) until the exhaust cam sits in the bearing journals evenly.






20. Install the bearing caps in their proper location as shown.
21. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.

Exhaust Camshaft Bearing Cap Bolts Torque Sequence:

22. Install and uniformly tighten the ten bearing cap bolts in several passes in the sequence shown above. Final torque should be 19 N.m (14 ft.lbs).
23. Remove the service bolt (B).






24. Apply seal packing, to the cylinder head as shown in the image above.
25. Install the new gasket to the valve cover. Install the valve cover with the four grommets and nuts, torque to 13 N.m (9 ft.lbs).






26. Install the No.3 timing belt cover with the four mount bolts.
27. Install the No.1 idler pulley and tension spring.
28. Install the cam timing pulley, spark plugs, fuel injectors, and fuel rail.






29. Install the new gasket and the intake manifold with the two bolts and six nuts. Torque to 19 N.m (14 ft.lbs).






30. Install the manifold brace with the two mount bolts. Torque the 12mm bolt to 19Nm (14 ft.lbs) and the 14mm bolt to 42 N.m (31 ft.lbs) and connect the vacuum sensing hose.






31. Install the air tube with the two mount bolts.
32. Connect the air intake chamber air hose and the throttle body air hose.
33. On P/S equipped vehicles, connect the P/S pump air hose.
34. Install the cold start injector pipe. Install the throttle body.
35. Install the EGR modulator with the bolt.






36. Install the new gasket and the EGR valve with the union nut and two mount bolts. Torque the union nut to 59 Nm (43 ft.lbs) and the two mount bolts to 13 N.m (9 ft.lbs).
37. Install the vacuum hoses.
38. Install the new O-ring to the bypass pipe and apply a light coat of engine oil to the O-ring.






39. Install the new gasket and bypass pipe with the two nuts and two bolts. Torque to 9.3 N.m (82 in.lbs) and connect the water hoses.






40. Install the water outlet and new gasket with the two bolts. Torque to 15Nm (11 ft.lbs).
41. Connect the upper radiator hose and the water hoses.
42. Connect the emission control vacuum hoses and the water temperature sender gauge connector.
43. Connect the water temperature sensor connector and the cold start injector time switch connector.
44. Install the distributor.






45. Place the new gasket so that the rear mark is towards the back as shown.






46. Install the exhaust manifold and catalytic converter assembly with the two bolts and six nuts. Torque to 39 Nm (29 ft.lbs).






47. Install the catalytic converter brace with the two bolts and two nuts.






48. Install the manifold upper heat insulator with the six bolts and connect the oxygen sensor connector.
49. Connect the exhaust pipe to the catalytic converter.
50. Install the lower suspension crossmember.
51. Install the RH engine hanger.
52. Install the RF wheel and lower the vehicle to the ground.
53. Install the oil pressure gauge line, engine hangers and the alternator bracket. Torque hangers to 42 N.m (31 ft.lbs).
54. Install the alternator, the air cleaner assembly, the air flow meter, and the air cleaner hose.
55. Install the cruise control actuator and bracket.
56. Install the radiator reservoir tank.
57. Install the accelerator cable and adjust as necessary.
58. On A/T equipped vehicles, install the throttle cable and bracket. Adjust as necessary.
59. Install the upper suspension brace.
60. Fill the engine with 6.4 liters (6.8 quarts) of an approved, 50-50 coolant mix.
61. Connect the negative battery cable.
62. Start the engine and check for leaks.
63. Adjust valve clearance and ignition timing as necessary.
64. Road test vehicle listening for any abnormal noises, shock, slippage, correct shift points and smooth operation.
65. Recheck engine coolant level and oil level.