Assembly

ASSEMBLY OF CYLINDER HEAD
HINT:
- Thoroughly clean all parts to be assembled.
- Before installing the parts, apply new engine oil to all sliding and rotating surfaces.
- Replace all gaskets and oil seals with new ones.
1. INSTALL VALVES
(a) Insert the valve in the cylinder head valve guide bushing. Check that the valves are installed in the correct order.






(b) Using SST, install new oil seals on the valve guide bushings. SST 09201-41020
(c) Install the spring seat, spring and spring retainer.






(d) Using SST, compress the valve retainers and place two keepers around the valve stem. SST 09202-70010
(e) Using a plastic-faced hammer, lightly tap the valve stem tip.
2. INSTALL VALVE LIFTERS AND SHIMS






Check that the valve lifters rotates smoothly by hand.
3. INSTALL CAMSHAFTS AND OIL SEALS






(a) Apply MP grease to the lip of a new oil seal.
(b) Install the oil seal to the camshaft.
(c) Apply engine oil to all bearing journals.






(d) Place the camshafts on the cylinder head as shown in the illustration.

HINT: The exhaust camshaft has a distributor drive gear.






(e) Apply seal packing to the No.1 bearing caps as shown in the illustration. Seal packing: Part No.08826-00080 or equivalent

HINT: Install the No.1 bearing cap immediately after applying the seal packing.






(f) Place bearing caps on each journal with the front marks pointing toward the front and in numerical order from the front side.






(g) Temporarily install the bearing cap bolts in the several passes, in the sequence shown.






(h) Using SST, tap in the camshaft oil seal. SST 09223-50010

HINT: Be careful not to install the oil seal slantwise.






(i) Uniformily tighten the No.3 and No.7 bearing cap bolts in several passes, in the sequence shown.
Torque: 200 kg-cm (14 ft-lb, 20 N.m)






(j) Uniformily tighten other bearing cap bolts in several passes, in the sequence shown.
Torque: 200 kg-cm (14 ft-lb, 20 N.m)
(k) Check the camshaft thrust clearance.






4. INSTALL EGR COOLER
Install a new gasket and EGR cooler with the eight bolts.
Torque: 140 kg-cm (10 ft-lb, 14 N.m)






5. INSTALL HEATER UNION
(a) Install a new gasket, union, another gasket and union bolt to the cylinder head.
(b) Torque the union bolt.
Torque: 600 kg-cm (43 ft-lb, 59 N.m)
6. INSTALL NO.2 ENGINE HANGER AND GROUND STRAP
Torque: 400 kg-cm (29 ft-lb, 39 N.m)






7. INSTALL INTAKE MANIFOLD
(a) Position a new gasket on the cylinder head.
(b) Install the intake manifold and VSV with the two nuts and seven bolts.
(c) Install the EGR valve with the two nuts
(d) Torque the bolts and nuts.
Torque: 180 kg-cm (13 ft-lb, 18 N.m)
8. INSTALL DELIVERY PIPE WITH INJECTORS
(a) Install the six insulators into the injector hole of the cylinder head.






(b) Install the black rings on the upper portion of each of the three spacers. Then install the spacers on the delivery pipe mounting hole of the cylinder head.
(c) Place the injectors together with delivery pipe on the cylinder head.






(d) Check that the injectors rotate smoothly.






(e) Install and torque the three bolts.
Torque: 180 kg-cm (13 ft-lb, 18 N.m)
9. INSTALL ALTERNATOR BRACKET
Torque: 400 kg-cm (29 ft-lb, 39 N.m)
10. INSTALL NO.2 TIMING BELT COVER