Removal and Installation

REMOVAL
1. Remove Right-Hand (RH) engine under cover.
2. Drain engine coolant.

3. Disconnect front exhaust pipe.
Remove the 2 bolts and 2 compression springs, and disconnect the front exhaust pipe.
4. Automatic Transaxle (A/T): Disconnect throttle cable.
5. Disconnect accelerator cable.
6. Disconnect Vacuum Switching Valve (VSV) for EVAP connector and bracket.
7. Remove air cleaner assembly with air intake connector.

8. Disconnect fuel hose.
Remove the union bolt and gaskets, and disconnect the fuel inlet hose.

NOTE: Catch leaking fuel in a container.

9. w/Power Steering (PS):
Remove PS pump and pump bracket without disconnecting hoses.
(a) Loosen the 2 bolts, and remove the PS drive belt.

(b) Remove the 2 bolts, and disconnect the PS pump from the engine.

NOTE: Put aside the PS pump, and suspend it.

Remove idler pulley bracket.
(a) Loosen the idler pulley mounting nut and adjusting bolt, and remove the drive belt.
(b) Remove the 3 bolts and idler pulley bracket.
11. Remove ignition coils and spark plugs.
12. Remove throttle body.
13. Remove camshaft position sensor.
14. Remove water inlet and outlet housing.
(a) Disconnect these connectors:
^ Engine coolant temperature sender gauge connector.
^ Engine coolant temperature sensor connector.
^ Fan engine coolant temperature switch connector.
(b) Disconnect these hoses:
^ 2 radiator hoses.
^ Water inlet hose.
^ Heater outlet hose.

(c) Remove the bolt, 2 nuts, the water inlet and outlet housing.
15. Remove exhaust manifold.
(a) Remove the 3 bolts and heat insulator.
(b) Remove the bolt, 2 nuts and exhaust manifold stay.

(c) Remote the 6 nuts, exhaust manifold and gasket.
16. Remove delivery pipe and injectors.
17. Disconnect brake booster and map vacuum hoses.
18. Remove intake manifold.
(a) Disconnect the engine wire clamps from the intake manifold stay.
(b) Remove the bolt, nut and intake manifold stay.

(c) Remove the 2 bolts, 3 nuts, intake manifold and gasket with air pipe.
19. Remove cylinder head cover.
(a) Remove the oil filler cap.

(b) Remove the 5 cap nuts and seal washers.
(c) Pry out the cylinder head cover, and remove the cover and gasket.
20. Remove charcoal canister.
21. Remove No. 2 timing belt cover.
Remove the 4 bolts, No. 2 timing belt cover and gasket.
22. Remove generator drive belt.
Loosen the pivot nut and adjusting bolt, and remove the generator drive belt.
23. Remove No. 3 timing belt cover from No. 1 timing belt cover.
24. Set No. 1 cylinder to Top Dead Center (TDC)/compression.

25. Remove timing belt from camshaft timing pulley.
(a) Loosen the mount bolt of the No. 1 idler pulley and shift pulley toward the left as far as it will go and then temporarily tighten it.

CAUTION: Be careful not to damage the timing belt.

(b) Remove the timing belt from the camshaft timing pulley.
26. Remove No. 2 idler pulley.

Remove the bolt and idler pulley.

CAUTION:
^ Support the timing belt, so the meshing of the crankshaft timing pulley and timing belt does not shift.
^ Be careful not to drop anything inside the timing belt cover.
^ Do not allow the belt to come into contact with oil, water or duct.

27. Remove camshaft timing pulley.

Secure the hexagonal portion of the camshaft, and remove the bolt and pulley.
28. Remove intake and exhaust camshafts.

CAUTION: Since the thrust clearance of the camshaft is small, the camshaft must be held level while it is being removed. 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) Set the intake camshaft as shown in the illustration so that the service bolt holes of the intake camshaft gears are directly above.

NOTE: This helps to lift the exhaust camshaft levelly and evenly by pushing No. 2 and No. 4 cylinder cam lobes of the intake camshaft toward their valve lifters.

(b) Remove the 4 bolts, No. 1 and No. 2 bearing caps.
(c) Remove the oil seal and housing plug.

(d) Secure the intake camshaft sub-gear to the main gear with a service bolt.
Recommended service bolt:
Thread diameter: 6 mm
Thread pitch: 1.0 mm
Bolt length: 16 - 20 mm (0.63 - 0.79 inch)

NOTE: When removing the camshaft, make sure that the torsional spring force of the sub-gear has been eliminated by the above operation.

(e) Uniformly loosen and remove the 8 No. 3 bearing cap bolts, in several passes, in the sequence shown.
(f) Remove the 4 bearing caps and exhaust camshaft.

NOTE: If the camshaft is not being lifted out straight and level, reinstall the bearing cap with the 2 bolts. Then alternately loosen and remove the bearing cap bolts with the camshaft gear pulled up.

CAUTION: Do not pry on or attempt to force the camshaft with a tool or other object.

(g) Uniformly loosen and remove the 8 No. 3 bearing cap bolts, in several passes, in the sequence shown.
(h) Remove the 4 bearing caps and intake camshaft.

NOTE: If the camshaft is not being lifted out straight and level, reinstall the bearing cap with the 2 bolts. Then alternately loosen and remove the 2 bearing cap bolts with the camshaft gear pulled up.

CAUTION: Do not pry on or attempt to force the camshaft with a tool or other object.

29. Disassemble intake camshaft.
(a) Mount the hexagon head portion of the camshaft in a soft jaw vise.

CAUTION: Be careful not to damage the camshaft.

(b) Using Special Service Tool (SST), turn the sub-gear clockwise, and remove the service bolt.
SST 09960 - 10010 (09962 - 0100, 09963 - 00500) or equivalent.
(c) Using snap ring pliers, remove the snap ring.

(d) Remove these parts:
(1) Wave washer.
(2) Camshaft sub-gear.
(3) Camshaft gear spring.

30. Remove cylinder head.

(a) Using a bi-hexagon wrench 8 mm, uniformly loosen and remove the 10 cylinder head bolts, in several passes, in the sequence shown.

CAUTION: Cylinder head warpage or cracking could result from removing bolts in incorrect order.

(b) Lift the cylinder head from the dowels on the cylinder block and place the head on wooden blocks on a bench.

NOTE: If the cylinder head is difficult to lift off, pry with a screwdriver between the cylinder head and block saliences.

CAUTION: Be careful not to damage the contact surfaces of the cylinder head and cylinder block.

INSTALLATION
1. Install cylinder head.
A. Place Cylinder Head On Cylinder Block.

(a) Place a new cylinder head gasket in position on the cylinder block.

CAUTION: Be careful of the installation direction.

(b) Place the cylinder head in position on the cylinder head gasket.
B. Install Cylinder Head Bolts.

NOTE:
^ The cylinder head bolts are tightened in 2 progressive steps (steps (b) and (d)).
^ If any cylinder head bolt is broken or deformed, replace it.

Cylinder Head Bolts Torque Sequence:

^ There are 2 lengths of cylinder head bolts, long (A) and short (B).

(a) Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
(b) First, using a hi-hexagon wrench 8 mm, install and uniformly tighten the 10 cylinder head bolts, in several passes, in the sequence shown.
Torque: 45 Nm (450 kg.cm, 33 ft. lbs.)
If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt.
(c) Mark the front of the cylinder head bolt head with paint.

(d) Retighten the cylinder head bolts 90� in the numerical order shown.
(e) Check that the painted mark is now at a 90� angle to front.
2. Assemble intake camshaft.
(a) Mount the hexagonal wrench head portion of the camshaft in a vise.

CAUTION: Be careful not to damage the camshaft.

(b) Install these parts:
(1) Camshaft gear spring.
(2) Camshaft sub-gear.
(3) Wave washer.

NOTE: Align the pins on the gears with the gear spring ends.

(c) Using snap ring pliers, install the snap ring.

(d) Using SST, align the holes of the camshaft main gear and sub-gear by turning camshaft sub-gear clockwise, and install a service bolt.
SST 09960 - 10010 (09962 - 0100, 09963 - 00500) or equivalent.
3. Install intake and exhaust camshafts.

CAUTION: 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 thrust portion of intake camshaft.

(b) Place the intake camshaft as shown in the illustration so that the service bolt of the intake camshaft gears are directly above.

NOTE: This helps to lift the intake camshaft in a level and uniform manner by pushing No. 3 and No. 4 cylinder cam lobes of the intake camshaft toward their vale lifters.

(c) Install the 4 bearing caps in their proper locations.
(d) Temporarily tighten the bearing cap bolts uniformly and alternately, in several passes, in the sequence shown until the bearing caps are snug with the cylinder head.
(e) Apply engine oil to thrust portion of the exhaust camshaft.

(f) Engage the exhaust camshaft gear to the intake camshaft gear by matching the timing marks on each gear.

CAUTION: There are also assembly reference marks on each gear as shown in the illustration. Do not use these marks.

(g) Roll down the exhaust camshaft onto the bearing journals while engaging gears with each other.

NOTE: The above angle allows the No. 2 and No. 4 cylinder cam lobes of the exhaust camshaft to push their valve lifters evenly.

(h) Lightly push the exhaust camshaft gear without applying excessive force.

(i) Install the 4 bearing caps in their proper locations.
(j) Temporarily tighten the bearing cap bolts uniform' and alternately, in several passes, in the sequence shown until the bearing caps are snug with the cylinder head.
(k) Remove the service bolt.
(l) Clean the installed surfaces of the No. 2 bearing cap and cylinder head with cleaner.

(m) Apply seal packing to the No. 2 bearing cap as shown.
Seal packing: Part No. 08826 - 00080 or equivalent.
(n) Place the No. 2 bearing cap in its proper location. When doing this, check that there is no gap between the cylinder head and the contact surface of bearing cap.

(o) Temporarily tighten the bearing cap bolts, alternately tightening the left and right bolts uniformly.
(p) Install the camshaft housing plug.

(q) Install and uniformly tighten the 10 bearing cap bolts, in several passes, in the sequence shown.
Torque: 13 Nm (130 kg.cm, 9 ft. lbs.)

(r) Apply MP grease to a new camshaft oil seal lip.

(s) Install the oil seal as far as the deepest part of the cylinder head.
(t) Clean the installed surfaces of the No. 1 bearing cap and cylinder head with cleaner.

(u) Apply seal packing to the No. 1 bearing cap as shown.
Seal packing: Part No. 08826 - 00080 or equivalent.
(v) Place the No. 1 bearing cap in its proper location. When doing this, check that there is no gap between the cylinder head and the contact surface of bearing cap.

(w) Temporarily tighten the bearing cap bolts, alternately tightening the left and right bolts uniformly.

(x) Install and uniformly tighten the 10 bearing cap bolts, in several passes, in the sequence shown.
Torque: 13 Nm (130 kg.cm, ft. lbs.)

(y) Turn the camshaft 1 revolution and check that the timing marks of the camshaft gears are aligned.
4. Check and adjust valve clearance.
5. Install camshaft timing pulley.

(a) Align the camshaft knock pin with the knock pin groove on the pulley side with the 5E mark, and slid the pulley.
(b) Secure the hexagonal portion of the camshaft, and install and torque the bolt.
Torque: 51 Nm (510 kg.cm, 37 ft. lbs.)
6. Install No. 2 idler pulley.

Install the idler pulley with the bolt. Torque the bolt.
Torque: 28 Nm (280 kg.cm, 20 ft. lbs.)

NOTE: Remove any oil or water on the idler pulley and keep it clean.

7. Set No. 1 cylinder to TDC/compression.

(a) Turn the crankshaft pulley, and align its groove with timing mark "O" of the No. 1 timing belt cover.

(b) Turn the camshaft, and align the hole of the camshaft timing pulley on the side with the 5E mark with the timing mark of the bearing cap.
8. Install timing belt.

(a) Starting from the right hand side of the pulley and installing the belt counterclockwise.

(b) Loosen the No. 1 idler pulley mounting bolt until the pulley is moved slightly by the spring tension.

(d) Check that each pulley aligns with the timing marks as shown in the illustration. If the timing marks do not align, remove the timing belt and reinstall it.
(e) Tighten the mounting bolt of the No. 1 idler pulley.
Torque: 18.5 Nm (185 kg.cm, 13 ft. lbs.)
9. Install No. 3 timing belt cover.
10. Install generator drive belt.
11. Install No. 2 timing belt cover.
(a) Install the gasket to the belt cover.

(b) Install the belt cover with the 4 bolts.
12. Install charcoal canister.
13. Install cylinder head cover.

(a) Apply seal packing to the cylinder head as shown in the illustration.
Seal packing: Part No. 08826 - 00080 or equivalent.
(b) Install the gasket to the cylinder head cover.

(c) Install the cylinder head cover with the 5 seal washers and nuts.
Torque: 7.0 Nm (70 kg.cm, 61 inch lbs.)
(d) Install the oil filler cap.
14. Install intake manifold.
(a) Install air pipe a new gasket and the intake manifold with the 2 bolts and 3 nuts.
Torque: 19.5 Nm (195 kg.cm, 14 ft. lbs.)

(b) Install the manifold stay with the bolt and nut.
Torque: 20 Nm (200 kg.cm, 15 ft. lbs.)
(c) Connect the engine wire clamps to the intake manifold stay.
15. Connect brake booster and map vacuum hoses.
16. Install injectors and delivery pipe.
17. Install exhaust manifold.

(a) Install a new gasket and the exhaust manifold with the 6 nuts. Uniformly tighten the nuts in several passes.
Torque: 48 Nm (480 kg.cm, 35 ft. lbs.)
(b) Place the exhaust manifold stay snug against the cylinder block and exhaust manifold.

(c) First, tighten the bolt (A) and then the 2 nuts.
Torque: 40 Nm (400 kg.cm, 29 ft. lbs.)
(d) Install the heat insulator with the 3 bolts.
Torque: 8.0 Nm (80 kg.cm, 60 inch lbs.)
18. Install water inlet and outlet housing.
(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contacting surfaces of the water outlet housing and cylinder head.
^ Using a razor blade and gasket scraper, remove all the packing (FIPG) material from the gasket surfaces.
^ Thoroughly clean all components to remove all the loose material.
^ Clean both sealing surfaces with a non-residue solvent.

(b) Apply seal packing to the water outlet housing as shown in the illustration.
Seal packing: Part No. 08826 - 00100, THREE BOND 1282B or equivalent.
^ Install a nozzle that has been cut to a 2 - 3 mm (0.08 - 0.12 inch) opening.

NOTE: Avoid applying an excess amount to the surface. Be especially careful near oil passages.
^ Parts must be assembled within 15 minutes of application. Otherwise, the material must be removed and reapplied.
^ Immediately remove nozzle from tube and reins tall cap.
^ Do not pour in any coolant until at least 2 hours after installation is completed.

(c) Install the water outlet housing with the bolt and 2 nuts.
Torque: 17.5 Nm (175 kg.cm, 13 ft. lbs.)
(d) Connect these hoses:
^ 2 radiator hoses.
^ Water inlet hose.
^ Heater outlet hose.
(e) Connect these connectors:
^ Engine coolant temperature sender gauge connector.
^ Engine coolant temperature sensor connector.
^ Fan engine coolant temperature switch connector.
19. Install camshaft position sensor.
(a) Install a new O-ring to the position sensor.

(b) Install the position sensor with the bolt.
Torque: 8.0 Nm (80 kg.cm, 69 inch lbs.)
(c) Connect the position sensor connectors.
20. Install throttle body.
21. Install ignition coils and spark plugs.
22. w/ A/C and w/o PS:
Install idler pulley bracket.

(a) Install the idler pulley bracket with the 3 bolts.
Torque:
12 mm head bolt: 27 Nm (275 kg.cm, 20 ft. lbs.)
14 mm head bolt: 37 Nm (375 kg.cm, 27 ft. lbs.)
(b) Install and adjust the drive belt.
23. w/PS:
Install PS pump bracket and PS pump.

(a) Install the PS pump bracket with the 3 bolts.
Torque: 44 Nm (440 kg.cm, 32 ft. lbs.)
(b) Temporarily install the PS pump and drive belt with the 2 bolts.
(c) Adjust the belt tension.
24. Connect fuel hose.

Connect the fuel inlet hose with the union bolt and 2 new gaskets.
Torque: 29 Nm (300 kg.cm, 22 ft. lbs.)
25. Install air cleaner assembly with air intake connector.
26. Install VSV for EVAP connector.
27. Install accelerator cable, and adjust it.
28. A/T:
Connect throttle cable, and adjust it.
29. Connect front exhaust pipe.
(a) Place a new gasket on the exhaust pipe.

(b) Connect the exhaust pipe to the exhaust manifold with the 2 compression spring and 2 bolts.
Torque: 62 Nm (630 kg.cm, 46 ft. lbs.)
30. Install RH engine under cover.
31. Fill with engine coolant.
32. Start engine and check for leaks.
33. Perform engine adjustment.
34. Perform road test.
Check for abnormal noise, shock, slippage, correct shift points and smooth operation.
35. Recheck engine coolant and engine oil levels.