Cylinder Head Assembly: Service and Repair

1. Install cylinder head

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

Notice: Be careful of the installation direction.

(b) Place the cylinder head in position on the cylinder head gasket.
(c) Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.

(d) Using SST. install and uniformly tighten the ten cylinder head bolts in several passes in the sequence shown.

Torque: 610 kg-cm (44 ft-lbs 60 N.m)

Hint: Cylinder head bolts are in length of 90mm (3.54in.)and 108 mm (4.25 in.). Install the 90mm (3.54in.) bolts (A) in intake manifold side positions. Install the 108 mm (4.25 in.) bolts (B) in exhaust manifold side positions.

2. Assemble exhaust camshaft.

(a) Mount the hexagonal wrench head portion of the camshaft in a vise.

Notice: Be careful not to damage the camshaft.

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

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

(d) Insert service bolts (A) and (B) into the service hole of the camshaft sub-gear.
(e) Using a screwdriver, align the' holes of the camshaft main gear and sub-gear by turning camshaft sub- gear clockwise, and install a service bolt (C).

Notice: Be careful not to damage the camshaft.

3. Install camshafts

Notice: 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 exhaust camshaft.

(a) Apply MP grease to the thrust portion of the camshaft.
(b) Place the intake camshaft so the knock pin is located slightly counterclockwise from the vertical axis of the camshaft.

Hint: The above angle allows the No.1 and No.3 cylinder cam lobes of the exhaust camshaft to push their valve lifters evenly.

(c) Remove any old packing (FIPG) material.

(d) Apply seal packing to the cylinder head as shown in the figure.

(e) Install the five bearing caps in their proper locations.
(f) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.

(g) Install and uniformly tighten the ten bearing cap bolts in several passes in the sequence shown.

Torque: 130 kg-cm (9 ft-lb, 13 N.m)

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

(i) Using SST, tap in the oil seal.

B. Install intake camshaft.

(a) Set the intake camshaft so the knock pin is slightly above the top of the cylinder head.
(b) Apply MP grease to the thrust portion of the camshaft.

(c) Engage the intake camshaft gear to the exhaust camshaft gear by matching the assembly installation marks on each gear.

Notice: There are also timing marks (for TDC) on each gear as shown in the illustration. Do not use these marks.

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

Hint: The above angle allows the No.1 and No.3 cylinder cam lobes of the intake camshaft to push their valve lifters evenly.

(e) Install the four bearing caps in their proper locations.
(f) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.

(g) Install and uniformly tighten the eight bearing cap bolts in several passes in the sequence shown.

Torque: 130 kg-cm (9 ft-lb. 13 N.m)

(h) Remove the service bolt (C).

(i) Install the No.1 bearing cap with the arrow mark facing forward.

Notice: If the No.1 bearing cap does not fit properly. push the camshaft gear backwards by prying apart the cylinder head and camshaft gear with a screwdriver.

(j) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
(k) Install and alternately tighten the two bolts in several passes.

Torque: 130 kg-cm (9 ft-lb. 13 N.m)

(l) Turn the exhaust camshaft clockwise. and set it with knock pin facing upward.

(m) Check that the timing marks of the camshaft gears are aligned.

Hint: The assembly installation marks are on upside.

4. 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 0.15-0.25 mm (0.006-0.010 in.) Exhaust 0.20-0.30 mm (0.008-0.012 in.)

5. Install P/S drive belt adjusting strut
Install the adjusting strut with the two bolts.

Torque: 400 kg-cm (29 ft-lb, 39 N.m)

6. Install engine hangers.
Install the engine hanger with the bolt. Install the two engine hangers.

Torque:280 kg-cm (20 ft-lb. 27 N.m)

7. Install fan belt adjusting bar.

Install the adjusting bar with the two bolts.

Torque: 200 kg-cm (14 ft-lb, 20 N.m)

8. Install camshaft timing pulley.
9. Install timing belt

10. Install semi-circular plug
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the circular plug.

(c) Install the semi-circular plug to the cylinder head.
11. Install cylinder head cover.
(a) Remove any old packing (FIPG) material.

(b) Apply seal packing to the cylinder head as shown in the figure.

(c) Install the gasket to the head cover.
(d) Install the head cover with the three grommets and cap nuts.

Torque: 80 kg-cm (69 in.lb. 7.8 N.m)

12. Install intake manifold

(a) Install a new gasket and the intake manifold with the seven bolts and two nuts.

Torque: 195 kg-cm (14 ft-lb. 19 N.m)

(b) Connect the PCV hose to PCV valve on the cylinder head.

(c) Install the manifold stay with the two bolts.

Torque: 12 mm bolt head 195 kg-cm (14 ft-lb. 19 N.m) 14 mm bolt head 400 kg-cm (29 ft-lb. 39 N.m)

13. Install air pipe.

(a) Install the air pipe with the two nuts.

(b) Connect the following hoses:
(1) Water inlet pipe water by-pass hose
(2) Fuel return hose (from fuel filter)

14. Install EGR valve
Install the EGR valve with the two nuts. Torque: 130 kg-cm (9 ft-lb. 13 N.m)

15. Install vacuum pipe. EGR vacuum modulator and EGR VSV

(a) Install the vacuum pipe. vacuum modulator and VSV assembly with the two nuts.

(b) Connect the following hoses:
(1) Two vacuum hoses (from EGR vacuum modulator) to EGR valve
(2) Vacuum hose (from EGR VSV) to EGR valve
16. Install Engine wire to intake manifold.

(a) Install the engine wire with the three bolts.

(b) Install the engine wire on the engine to vacuum pipe with the wire clamp.
(c) Connect the following connectors:

(1) EGR VSV connector
(2) (CALIF. only) EGR gas temperature sensor connector
(3) Vacuum sensor connector
17. Install engine wire to NO.3 timing belt cover

(a) Install the wire clamp on the engine wire to the wire bracket.
(b) Install the engine wire with the bolt.
(c) Connect the following connectors and wire:
(1) Alternator connector
(2) Alternator wire
(3) Oil pressure switch connector
(4) A/C compressor connector
18. Install ACV

(a) Install a new O-ring to the ACV.
(b) Apply soapy water to the O-ring.
(c) Install the ACV with the bolt and nut.
(d) Connect the air hose to the air pipe.

Torque: 130 kg-cm (9 ft-lb, 13 N.m)

19. Install injectors and delivery pipe
20. Install cold start injector
21. Install cold start injector pipe
22. Install throttle body
23. Install P/S pump

(a) Install the P/S pump and drive belt with the two bolts.

Torque: 400 kg-cm (29 ft-lb. 39 N.m)

(b) Connect the following hoses:
(1) Air hose to air pipe
(2) Air hose to intake manifold
24. Connect vacuum hoses

(a) Vacuum sensor hose to gas filter on intake manifold
(b) Brake booster vacuum hose to intake manifold
(c) Three A/C vacuum hoses to ASV on intake manifold
(d) A/C vacuum hose to air pipe
25. Install water inlet and inlet housing
(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the inlet housing and cylinder head.

Using a razor blade and gasket scraper, remove all the oil packing (FIPG) material from the gasket surfaces and sealing groove. Thoroughly clean all components to remove all the loose material. Using a non-residue cloth, clean both sealing surfaces.

(b) Apply seal packing to the inlet housing groove.
Install a nozzle that has been cut to a 2-3 mm (0.08- 0.12 in.) opening.

Hint: Avoid applying an excessive amount to the surface.

Parts must be assembled within 15 minutes of application. Otherwise the material must be removed and reapplied. Immediately remove nozzle from the tube and reinstall cap.

(c) Install the water inlet and inlet housing assembly with the bolt and two nuts.

Torque: 200 kg-cm (14 ft-lb. 20 N.m)

(d) Connect the following hoses:
(1) Lower radiator hose
(2) Water inlet pipe hose
(3) Auxiliary air valve water by-pass hose
(4) Heater water hose
(5) EVAP BVSV vacuum hose (from P port of throttle body)
(6) EVAP BVSV vacuum hose (from charcoal canister)
(e) Connect the following connectors:
(1) Water temperature sender gauge connector
(2) Water temperature sensor connector
(3) Cold start injector time switch connector
26. Install water outlet
(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the water outlet and cylinder head.
Using a razor blade and gasket scraper, remove all the oil packing (FIPG) material from the gasket surfaces and sealing groove. Thoroughly clean all components to remove all the loose material. Using a non-residue cloth, clean both sealing surfaces.

(b) Apply seal packing to the water outlet groove.
Install a nozzle that has been cut to a 2-3 mm (0.08- 0.12 in.) opening.

Hint: Avoid applying an excessive amount to the surface.

Parts must be assembled within 15 minutes of application. Otherwise the material must be removed and reapplied. Immediately remove nozzle from the tube and reinstall cap.

(c) Install the water outlet with the two bolts.

Torque:150 kg-cm (11 ft-lb. 15 N.m)

(d) Connect the upper radiator hose to the water outlet.
27. Install exhaust manifold

(a) Install the lower heat insulator to the exhaust manifold with the three bolts.

(b) Install a new gasket and the exhaust manifold with the two bolts and three new nuts.

Torque: 250 kg-cm (18 ft-lb. 25 N.m)

(d) Install the upper heat insulator with the five bolts.