Cylinder Head Installation
1. Install cylinder head.a. Place a new cylinder head gasket in position on the cylinder block.
Note: Position crankshaft at No.1 TDC.
CAUTION: Be careful of the installation direction.
b. Place the cylinder head in position on the cylinder head gasket.
2. Install cylinder head bolts.
NOTE:
^ The cylinder head bolts are tightened in two progressive steps (steps (b) and (d)).
^ If any cylinder head bolt is broken or deformed, replace it.
a. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
b. Using SST 09011-38121, install and uniformly tighten the ten cylinder head bolts and plate washers in several passes, in the sequence shown.
Torque: 49 Nm (36 ft lb)
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, turn 90°, in the numerical order shown.
e. Check that the painted mark is now at a 90° angle to front.
3. Install spark plug tubes.
a. Clean the cylinder head tube holes of any residual adhesive, oil or foreign particles. Remove any oil with kerosene or gasoline.
b. Screw the threads of the spark plug tube coated with adhesive into the cylinder head.
c. Using the spark plug tube nut and a 30 mm socket wrench, tighten the spark plug tubes.
Torque: 39 Nm (29 ft lb)
4. Install 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. Install intake camshaft.
1. Apply multipurpose (Mp) grease to the thrust portion of the camshaft.
2. Place the intake camshaft at 80-115° BTDC of camshaft angle on the cylinder head.
NOTE: The above angle allows the No.1 and No.3 cylinder cam lobes of the intake camshaft to push their valve lifters evenly.
3. Apply seal packing to the No.1 bearing cap as shown. Seal packing: Part No.08826-00080 or equivalent
4. Install the bearing caps in their proper locations.
5. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
6. Install and uniformly tighten the ten bearing cap bolts in several passes, in the sequence shown.
Torque: 19 Nm (14 ft lb)
7. Apply Mp grease to a new oil seal lip.
8. Using SST 09223-46011, tap in the oil seal.
B. Install exhaust camshaft.
1. Set the knock pin of the intake camshaft at 10-45° BTDC of camshaft angle.
NOTE: The above angle allows the No.2 and No.4 cylinder cam lobes of the exhaust camshaft to push their valve liters evenly.
2. Apply MP grease to the thrust portion of the camshaft.
3. Engage the exhaust camshaft gear to the intake camshaft gear by matching the timing marks on each gear.
4. Roll down the exhaust camshaft onto the bearing journals while engaging gears with each other.
NOTE: There are also assembly reference marks on each gear as shown in the illustration. Do not use these marks.
5. Turn the intake camshaft clockwise or counterclockwise little by little until the exhaust camshaft sits in the bearing journals evenly without rocking the camshaft on the bearing journals.
NOTE: It is very important to replace the camshaft in the bearing journals evenly while tightening bearing caps in the subsequent steps.
6. Install the bearing caps in their proper locations.
7. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
8. Install and uniformly tighten the ten bearing cap bolts in several passes. in the sequence shown.
Torque: 19 Nm (14 ft lb)
9. Remove the service bolt (B).
5. Check and adjust valve clearance.
Turn the camshaft and position the cam lobe upward, and check and adjust the valve clearance. Valve clearance (Cold):
Intake:
0.19-0.29 mm (0.007-0.011 in.)
Exhaust:
0.28-0.38 mm (0.011-0.015 in.)
If clearance not within specifications adjust valve clearance.
6. Install semi-circular plugs.
a. Remove any old packing (Formed in Place Gasket (FIPG))material.
b. Apply seal packing to the semi-circular plug grooves. Seal packing:
Part No.08826-00080 or equivalent
c. Install the two semi-circular plugs to the cylinder head.
7. Install PCV valve and high - tension cords clamp.
8. Install cylinder head cover.
a. Remove any old packing (FIPG) material.
b. Apply seal packing to the cylinder head as shown in the illustration.
Seal packing: Part No.08826-00080 or equivalent
c. Install the gasket to the head cover.
d. Install the head cover with the four grommets and nuts. Uniformly tighten the nuts in several passes.
Torque: 23 Nm (17 ft lb)
NOTE: Install the grommets so that their markings are as shown in the illustration.
9. Install oil pressure switch, apply adhesive to two or three threads.
Adhesive: Part No. 08833 - 00080. THREE BOND 1324 or equivalent
10. Install the alternator bracket with the three bolts.
Torque: 42 Nm (31 ft lb)
11. Install the engine hanger with the bolt. Install the two engine hangers. Install the ground strap.
Torque: 25 Nm (18 ft lb)
12. Install the No.3 timing belt cover with the four bolts.
Torque: 7.8 Nm (69 in. lb)
13. Install No.1 idler pulley and tension spring.
14. Install camshaft timing pulley.
15. Install injector and delivery pipe.
16. Install intake manifold.
a. Install a new gasket and the intake manifold with the six bolts and two nuts. Uniformly tighten the bolts and nuts in several passes.
Torque: 19 Nm (14 ft lb)
b. Install the two manifold stays with the four bolts. Alternately tighten the bolts. Install the connector bracket (CALIF. only).
Torque:
12 mm head bolt 22 Nm (16 ft lb)
14 mm head bolt 42 Nm (31 ft lb)
c. Install the engine wire protector with the bolt.
d. Connect the two wire clamps to the wire brackets.
e. Connect the PCV hose to the PCV valve.
17. Install accelerator bracket.
18. Install Vacuum Switching Valve (VSV) for EGR.
19. Connect engine wire ground straps and connectors.
a. Two engine ground straps to intake manifold.
b. Knock sensor connector
c. VSV connector for EGR
20. Install air tube, Air Switching Valve (ASV) (for A/C) and vacuum pipe.
a. Install the air tube, ASV assembly and the vacuum hose bracket with the four bolts.
b. Install the vacuum pipe with the bolt.
c. Connect the following hoses:
(1) PS air hose to intake manifold.
(2) Two air hoses to air tube.
(3) (with A/C) Air hose to intake manifold.
(4) Vacuum hose to gas filter.
(5) Vacuum hose to fuel pressure regulator.
d. (with A/C) Connect the ASV connector.
21. Connect vacuum hoses.
a. Vacuum sensor hose to gas filter.
b. Brake booster vacuum hose to intake manifold.
c. (with Cruise Control System (with out ABS)) Actuator vacuum hose to intake manifold.
22. Install EGR valve and vacuum modulator.
a. Install a new gasket and the EGR valve with the union nut and two nuts.
Torque:
Union nut 59 Nm (43 ft lb)
Bolt 13 Nm (9 ft lb)
b. Install the EGR modulator to the clamp.
c. Connect the following hoses:
(1) Vacuum hose (from port Q of EGR vacuum modulator) to port G of VSV for EGR.
(2) Vacuum hose (from EGR valve) to port E of VSV for EGR.
(3) Vacuum hose to charcoal canister.
d. Install the vacuum hose clamp to the bracket.
e. (CALIF. only): Install the connector to the bracket. Connect the EGR gas temperature sensor connector.
23. Install throttle body with the four bolts.
Torque: 19 Nm (14 ft lb)
NOTE: Each bolt is indicated in the illustration.
Bolt length:
A 45 mm (1.77 in.)
B 55 mm (2.17 in.)
24. Install water by-pass pipe.
a. Install a new 0-ring to the by-pass pipe.
b. Apply soapy water on the 0-ring.
c. Install a new gasket and the by-pass pipe with the two nuts and two bolts.
Torque(Nut): 9.3 Nm (82 in. lb)
d. Connect the following hoses:
(1) Idle Speed Control (ISC) water by-pass hose.
(2) Heater water hose.
(3) (with Oil Cooler) Two oil cooler water by-pass hoses.
e. (with Oil Cooler) Install the water by-pass hose heat protector.
25. Install water outlet.
a. Install a new gasket and the water outlet with the two bolts.
Torque: 15 Nm (11 ft lb)
b. Connect the following hoses:
(1) Upper radiator hose.
(2) Water by-pass pipe hose.
(3) Heater water hose.
(4) ISC water by-pass hose.
(5) Evaporative Emission (EVAP) Bimetal Vacuum Switching Valve (BVSV) vacuum hose (from port P of throttle body).
(6) EVAP BVSV vacuum hose (from charcoal canister).
c. Connect the following connectors:
(1) Water temperature sender gauge connector.
(2) Water temperature sensor connector.
26. Assemble exhaust manifold and catalytic converter. If previously separated.
a. Place the cushion, retainer and a new gasket on the catalytic converter.
b. Install the catalytic converter to the exhaust manifold with the three bolts and two nuts.
Torque: 29 Nm (22 ft lb)
c. Install the lower manifold head insulator with the five bolts.
d. Install the two catalytic converter heat insulators with the eight bolts.
27. Install exhaust manifold and catalytic converter assembly.
a. Install a new gasket, the exhaust manifold and catalytic converter assembly with the six new nuts. Uniformly tighten the nuts in several passes.
Torque: 49 Nm (36 ft lb)
b. Install the catalytic converter stay with the two bolts and two new nuts. Alternately tighten the bolts and nut.
Torque: 42 Nm (31 ft lb)
c. Install the manifold upper heat insulator with the six bolts.
28. (CALIF. only) Install sub-oxygen sensor.
29. Install oxygen sensor (main).
30. Install front exhaust pipe.
31. Install suspension lower crossmember.
Torque: 152 Nm (112 ft lb)
32. Install engine under covers.
33. Install distributor.
34. Install alternator.
35. Install air cleaner cap and hose.
36. (with Cruise Control System) Install cruise control actuator.
37. Install accelerator cable, and adjust it.
38. (A/T) Connect throttle cable, and adjust it.
39. Connect cable to negative terminal of battery.
40. Fill with engine coolant
Capacity:
M/T 6.2 liters (6.6 qts)
A/T 6.1 liters (6.4 qts)
41. Start engine and check for leaks.
Fig. 70 Shorting Check Connector Terminals:
42. Adjust ignition timing.
Ignition timing: 10° BTDC at idle
(with Terminals TE1 and E1 connected)
43. Perform road test. Check for abnormal noise, shock, slippage, correct shift points and smooth operation.
44. Recheck engine coolant level, engine oil and transaxle fluid levels.