Installation

1. Remove gasket material using a suitable gasket scraper, remove all the gasket material from the cylinder block surface.

NOTE: Be careful not to scratch the cylinder block contact surface.






2. Clean top surfaces of pistons and cylinder block as follows:
(a) Turn the crankshaft, and bring each piston to top dead center (TDC). Using a gasket scraper, remove all the carbon from the piston top surface.
(b) Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
(c) Using compressed air, blow carbon and oil from the bolt holes.

WARNING: Protect your eyes when using high-pressure compressed air.






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

NOTE: Be sure to install it correctly.

4. Place the cylinder head in position on the cylinder head gasket.
5. Install cylinder head bolts as follows:






NOTE:
- The cylinder head bolts are tightened in 3 progressive steps.
- If any of bolts break or deform, replace them.

(a) Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
(b) Install one of the 14 plate washers to each cylinder head bolt.






(c) Using a 10 mm hi-hexagon wrench, uniformly tighten the cylinder head bolts, in several passes, in the sequence shown to 34 Nm (350 kg.cm, 25 ft.lb).

NOTE: If any of the bolts do not meet the torque specification, replace the bolt.

(d) Mark the front of the cylinder head bolt head with paint.
(e) Retighten the cylinder head bolts 90° in the numerical order shown.
(f) Retighten cylinder head bolts by an additional 90° shown.
(g) Check that the painted mark is now turned to the rear.
6. Install camshafts as follows:
(a) Apply engine oil to the thrust portion of the camshaft.






(b) Place the camshaft on the cylinder head with the cam lobe facing up as shown.






(c) Place the No.3 and No.7 bearing caps in their proper location.
(d) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
(e) Hand tighten these bearing cap bolts uniformly and alternately, in several passes, until the bearing caps are snug with the cylinder head.






(f) Apply MP grease to a new camshaft oil seal lip.
(g) Install the 2 oil seals to the camshafts.






(h) Clean the installed surfaces of the No.1 bearing cap and cylinder head with cleaner.
(i) Apply seal packing part No. 08826-00080 or equivalent to the No.1 bearing cap as shown.






(j) Install the No.1, No.2, No.4, No.5 and No.6 bearing caps in their proper locations.
(k) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.






(l) Install and uniformly tighten the 14 bearing cap bolt on one side, in several passes, in the sequence shown to 20 Nm (200 kg.cm, 14 ft.lb).






(m) Using seal driver Special Service Tool (SST) No. 09316-60011 (09316-00011, 09316-00051), or equivalent, push the 2 oil seals in as far as they can go.






(n) Rotate the camshaft with a wrench at the hexagon position, bring the forward straight pin up.
(o) Loosen the 12 bearing cap bolts at arrows as shown in illustration, until they can be turned by hand, then retighten in several passes to 20 Nm (200 kg.cm, 14 ft.lb).






(p) Turn the camshaft 1/3 of a revolution.
(q) Loosen the 8 bearing cap bolts as shown, until they can be turned by hand, retighten in several passes to 20 Nm (200 kg.cm, 14 ft.lb).






(r) Turn the camshaft a further 1/3 of a revolution.
(s) Loosen the 8 bearing cap bolts as shown, until they can be turned by hand, retighten in several passes to 20 Nm (200 kg.cm, 14 ft.lb).
7. Check and adjust valve clearance, refer to Adjustments under Camshaft. Lifters and Pushrods.
8. Install No.4 timing belt cover tighten to 7.8 Nm (80 kg.cm, 69 in.lb).






9. Install camshaft timing pulleys tighten to 79 Nm (80 kg.cm, 59 ft.lb)
10. Install No.3, No.1 and No.2 cylinder head covers, refer to procedure in Adjustments under Camshaft. Lifters and Pushrods.
11. Install intake manifold tighten to 27 Nm (280 kg.cm, 20 ft.lb).
12. Install injectors and delivery pipe, refer to Powertrain Management.






13. Install fuel pipes as follows:
(a) Install the fuel inlet pipe with 2 new gaskets and the union bolt, tighten to 42 Nm (420 kg.cm, 30 ft.lb).
(b) Install the fuel return pipe with 2 new gaskets and the union bolt, tighten to 27 Nm (280 kg.cm, 20 ft.lb).
(c) Install the 2 clamp bolts to the intake manifold, tighten to 8.8 Nm (90 kg.cm, 78 in.lb).
14. Install fuel pressure pulsation damper, refer to Powertrain Management.
15. Install water outlet with no. 1 water bypass hose, tighten to 21 Nm (210 kg.cm, 15 ft.lb).
16. Connect engine wiring as follows:
(a) Install the engine wire protector to the intake manifold with the 3 nuts.
(b) Connect these connectors:
ECT sensor connector
ECT sender gauge connector
2 knock sensor connectors
Oil pressure switch connector
Oil level sensor connector
A/C compressor connector
6 injector connectors

NOTE: The No.1, No.3 and No.5 injector connectors are gray, and the No.2, No.4 and No.6 injector connectors are dark gray.






(c) Install the wire clamp to the intake manifold with the bolt.
(d) Install the 2 ground straps to the intake manifold with the bolts.
(e) Connect these connectors:
Heated oxygen sensor (bank 1 sensor 1) connector
Crankshaft position sensor connector
(f) Connect the wire clamp to the bracket.
17. Install vacuum control valve set, tighten to 21 Nm (210 kg.cm, 15 ft.lb).
18. Install oil dipsticks and guides for engine and transmission.
19. Install intake manifold stay, tighten to39 Nm (400 kg.cm, 29 ft.lb).
20. Install power steering pump rear stay, tighten to 39 Nm (400 kg.cm, 29 ft.lb).
21. Connect fuel return hose.






22. install air intake chamber as follows:
(a) Install a new gasket and the intake chamber with the 5 bolts and nut, tighten to 27 Nm (280 kg.cm, 20 ft.lb).
(b) Install the accelerator bracket and hose clamp with the 2 bolts.
(c) Install the brake booster union with 2 new gaskets and the union bolt.






23. Install the No.1 and No.2 air intake chamber stays, tighten to 18 Nm (185 kg.cm, 13 ft.lb).

NOTE: The No.1 stay is marked "F" and No.2 stay is marked with ART.






24. install Diagnostic Link Connector 1 (DLC 1) bracket and Vacuum Solenoid Valve (VSV) assembly as follows:
(a) Install the DLC1 bracket and VSV assembly with the bolt.
(b) Connect these hoses:
PS air hose to air intake chamber (1).
Vacuum sensing hose to fuel pressure regulator (2).
Vacuum hose to air intake chamber (3).
(c) Connect the VSV connector.
(d) Connect the DLC 1 to the bracket.
25. Install Timing Belt, refer to Timing Components.
26. Install No.1 water bypass pipe and water by pass outlet, refer to Cooling System.
27. Install spark plugs, distributor and high-tension wires, refer to Powertrain Management.






28. Install intake air connector as follows:
(a) Install the No.1 vacuum pipe with the 3 bolts.
(b) Connect the vacuum hose to the intake air port.
(c) Place a new gasket so the protrusion face the air intake chamber, and set the intake air connector.
(d) Connect the vacuum hose to the No.1 vacuum pipe.
(e) Install the intake air connector with the 4 bolts and 2 nuts, then tighten to 27 Nm (280 kg.cm, 20 ft.lb).
29. Install No.2 vacuum pipe and VSV assembly, tighten to 27 Nm (280 kg.cm, 20 ft.lb).
30. Connect brake booster vacuum hose.
31. Install PCV hose.
32. Install EGR valve and vacuum modulator assembly as follows:
(a) Place a new gasket to the intake air connector.
(b) Install the EGR valve and vacuum modulator assembly with the 2 nuts, tighten to 21 Nm (210 kg.cm, 15 ft.lb).
(c) Connect the 3 vacuum hoses to the No.1 vacuum pipe.
(d) Install the bolt holding the vacuum modulator bracket to the intake air connector.
33. Install EGR gas temperature sensor, tighten to 20 Nm (200 kg.cm, 14 ft.lb).
34. Install EGR pipe as follows:
(a) Install the union nut of the EGR pipe hand tight.
(b) Install a new gasket and the EGR pipe with the 2 bolts, tighten to 27 Nm (280 kg.cm, 20 ft.lb).
(c) Tighten the union nut of the EGR pipe to 64 Nm (650 kg.cm, 47 ft.lb).
35. Install engine wire and heater water valve to cowl panel.
36. Install throttle body and throttle body bracket.
37. Install VSV for EGR.
38. Install air intake hose.
37. Install exhaust manifolds as follows:
(a) Install the No.1 and No.2 exhaust manifolds with new gaskets, then tighten to 39 Nm (400 kg.cm, 29 ft.lb).
(b) Connect the 2 heated oxygen sensor connectors.
40. Install No.2 Front exhaust pipe, refer to Exhaust System.
41. Install water pump pulley, fan, fluid coupling assembly and drive belt.
42. Install air cleaner, Mass Air Flow (MAF) meter and intake air connector pipe assembly.
43. Install air cleaner duct.
44. Connect control cables to throttle body.
45. Fill with engine coolant.
46. Start engine and check for leaks.
47. Check ignition timing, refer to Powertrain Management.
48. Install engine under cover.
49. Road test, check for abnormal noise, shock, slippage, correct shift points and smooth operation.
50. Recheck engine coolant level.