Cylinder Block Assembly: Service and Repair

1. Install the six new spark plug tube gaskets.






2. Apply seal packing, part No. 08826-00080 or equivalent, to the cylinder heads as shown.
3. Install new gaskets to the valve covers.






4. Install the valve covers using new seal washers. Torque to 5.9 Nm (52 in.lbs).






5. Install the No.3 timing belt cover and torque to 7.4 Nm (65 in.lbs).
6. Install the No.2 idler pulley, cam timing pulleys, timing belt, and spark plugs. Torque spark plugs to 18 Nm (13 ft.lbs).






7. Install the exhaust manifold inside heat shield.






8. Using a new gasket and new mount nuts, install the exhaust manifold. Torque to 39 Nm (29 ft.lbs).






9. Install the outside heat shield and connect the oxygen sensor connector.






10. Using a new gasket and new mount nuts, install the LH exhaust manifold. Torque to 39 Nm (29 ft.lbs).






11. Install the heat shield.






12. Using new gaskets, install the intake manifold, torque to 18 Nm (13 ft.lbs).






13. Install the No.2 idler pulley bracket brace. Torque to 18 Nm (13 ft.lbs).






14. Install the cylinder head rear plate.






15. Install the crossover pipe heat shield.






16. Using a new gasket, install the water bypass outlet, torque to 20 Nm (14 ft.lbs).
17. Connect the heater bypass hose, cold start injector time switch, and the water temperature switch.
18. Connect the upper radiator hose and the water temperature sensor connector.






19. Using a new gasket, install the water outlet. Torque to 8.3 Nm (73 in.lbs).
20. Install the injectors and fuel rail.

Fig. 10 Intake Manifold Removal:

21. Using new gaskets, install the intake chamber and torque to 43 Nm (32 ft.lbs).






22. Install the two intake chamber braces, torque to 37 Nm (27 ft.lbs).
23. Connect the PCV hose, vacuum sensing hose, A/C control valve air hose and, on California vehicles, the EGR gas temperature sensor connector.
24. Install the cold start injector tube.






25. Using new gaskets, install the crossover pipe, torque the nuts to 39 Nm (29 ft.lbs) and torque the bolts to 34 Nm (25 ft.lbs).
26. Install the distributor.






27. Install the vacuum pipe and connect the four BVSV vacuum hoses and the A/C control valve vacuum hose.





28. Using a new gasket, install the EGR valve and vacuum modulator. Torque to 18 Nm (13 ft.lbs) and install the four vacuum pipe hoses.






29. Using a new gasket, install the EGR pipe and torque the bolts to 18 Nm (13 ft.lbs) and the union bolt to 78 Nm (58 ft.lbs).
30. Install the throttle body, ISC valve, alternator, and the front exhaust pipe.
31. Install the RH engine lower cover, air cleaner hose and the cruise control actuator.
32. Install the accelerator cable and adjust as necessary.
33. On A/T equipped vehicles, install the throttle cable and adjust as necessary.
34. Fill the engine with coolant.
35. Connect the negative battery cable, start the engine and check for leaks.
36. Check and adjust timing as necessary.
37. Road test vehicle. Recheck engine coolant and oil levels and top off as necessary.