Part 1

INSTALLATION OF CYLINDER HEAD
1. INSTALL CYLINDER HEAD






(a) Apply seal packing to the two locations shown. Seal packing: Part No.08826-00080 or equivalent
(b) Place a new cylinder head gasket on the cylinder block.






NOTICE: Be careful of the installation direction.

(c) Place the cylinder head on the cylinder head gasket, and connect the No.5 water by-pass hose to the union.
(d) Apply a light coat of the engine oil on the threads and under the cylinder head bolts.






(e) Using SST, install and uniformly tighten the fourteen cylinder head bolts in several passes and in the sequence shown. SST 09043-38100
Torque: 800 kg-cm (58 ft-lb, 78 N.m)
2. INSTALL CAMSHAFT TIMING PULLEYS AND TIMING BELT
3. SET NO.1 CYLINDER TO TDC/COMPRESSION






Turn the crankshaft pulley and align its groove with the "0" mark on the No.1 timing belt cover.
4. INSTALL CAMSHAFT TIMING PULLEYS






(a) Align the timing pulley alignment mark with the No.2 timing belt cover alignment mark.
(b) Install the timing pulley.
(c) Install the straight pin into the hole.

HINT:

- When replacing the camshaft or the camshaft timing pulley: Align the center holes of the camshaft and timing pulleys, as shown in the illustration and insert the straight pin.
- When reusing the camshaft or camshaft timing pulleys: Check that the straight pin hole position is in the same position it was at disassembly, insert the straight pin.
(d) Install the plate washer and pulley bolt.






(e) Using SST to hold the pulley, torque the pulley bolt. SST 09278-54012
Torque: 500 kg-cm (36 ft-lb, 49 N.m)
(f) Check that the matchmarks on the camshaft timing pulley are aligned with those on the No.2 timing belt cover.
5. INSTALL TIMING BELT
(a) Install the timing belt to the intake camshaft timing pulley, the exhaust camshaft timing pulley and then the idler pulley.






(b) Check that the belt has tension as shown in the illustration.
(c) Loosen the idler pulley mount bolt until the pulley is moved slightly by the spring tension.



(d) Torque the idler pulley mount bolt.
Torque: 500 kg-cm (36 ft-lb, 49 N.m)






HINT: Check that the timing belt tension at A is equal to that at B. If not, readjust with the idler pulley.






(e) Turn the crankshaft pulley two revolutions clockwise from TDC to TDC.






(f) Check that the alignment marks on the camshaft timing pulleys are aligned with those on the No.2 timing belt cover. If the marks do not align, remove the timing belt and reinstall it.






6. CHECK TIMING BELT TENSION






(a) Turn both the intake and exhaust camshaft pulleys inward at the same time to slacken the timing belt at position A.
Turning torque: 200 kg-cm (14 ft-lb, 20 N.m)






(b) Measure the timing belt deflection as shown.
Belt deflection at 2 - 3 kg (4.4 - 6.6 lb, 20 - 29 N):
Cold
Used belt 5 - 7 mm (0.20- 0.28 in.)
New belt 4 - 6 mm (0.16-0.24 in.)
Hot (Reference) 3 - 5 mm (0.12-0.20 in.) If the measurement is not within specification, adjust by the idler pulley.
7. INSTALL NO.3 TIMING BELT COVER






Install the gasket and the belt cover with the five bolts and nut.
8. INSTALL PS BELT
9. INSTALL WATER PUMP PULLEY, FAN WITH FLUID COUPLING AND ALTERNATOR DRIVE BELT
(a) Install the water pump pulley and fan with fluid coupling with the four nuts.
(b) Place the drive belt on to each pulley.
(c) Stretch the belt tight and tighten the four nuts.
10. INSTALL A/C BELT
11. ADJUST DRIVE BELTS
Drive belt tension:
Alternator Used belt 115 ± 20lb
New belt 175 ± 5lb
PS pump Used belt 100 ± 20lb
New belt 160 ± 10lb
A/C Used belt 105 ± 10lb
New belt 160 ± 2Olb
12. INSTALL SPARK PLUGS
13. INSTALL CYLINDER HEAD COVERS






(a) Using SST, install the No.3 cylinder head cover. SST 09923-00010
Torque: 180 kg-cm (13 ft-lb, 18 N.m)






(b) Apply seal packing to the cylinder head as shown in the illustration. Seal packing: Part No.08826-00080 or equivalent






(c) Install the No.1 and No.2 cylinder head covers.
Torque: 25 kg-cm (22 in.- lb, 2.5 N.m)
14. INSTALL WATER OUTLET HOUSING






(a) Install a new gasket and water outlet housing with the bolt and two nuts.
(b) Connect the No.6 water by-pass hose.






(c) Install unions with No.4 water by-pass hose to the water outlet housing with new gaskets and union bolts.
15. INSTALL EXHAUST MANIFOLD






(a) Face a new exhaust gasket so the protrusion is facing the rear and install on the cylinder head.






(b) Install the exhaust manifold with the seven nuts.
Torque: 400 kg-cm (29 ft-lb, 39 N.m)
16. INSTALL OIL DIPSTICK
17. INSTALL DISTRIBUTOR






18. CHECK NO.1 CYLINDER TO TDC/COMPRESSION
19. INSTALL DISTRIBUTOR






(a) Install a new 0-ring to the distributor.

HINT: Always use a new 0-ring when installing the distributor.






(b)89GAlign the groove of the distributor housing with the protrusion on the driven gear
(c) Insert the distributor, aligning the center of the flange with that of the bolt hole on the cylinder head.
(d) Lightly tighten the hold-down bolt.
20. CONNECT DISTRIBUTOR CONNECTOR
21. CONNECT HIGH-TENSION CORDS TO SPARK PLUGS AND IGNITION COIL
22. INSTALL NO.2 FUEL PIPE






(a) Install the No.2 fuel pipe to the pressure regulator with the union bolt and new gaskets.
Torque: 250 kg-cm (18 ft-lb, 25 N.m)
(b) Install the No.2 fuel pipe to the delivery pipe with the bolt.
(c) Connect the fuel hose.
23. INSTALL NO.1 FUEL PIPE






(a) Install the No.1 fuel pipe to the delivery pipe with the union bolt and new gaskets.
Torque: 400 kg-cm (29 ft-lb, 25 N.m)
(b) Connect the No.1 fuel pipe to the intake manifold.
(c) Connect the No.1 fuel pipe to the fuel filter.
Torque: 300 kg-cm (22 ft-lb, 29 N.m)
24. INSTALL ENGINE WIRE
(a) Install the engine wire to each clamp.
(b) Connect the following connectors and wire:
- Oxygen sensor connector
- Oil pressure sender gauge connector
- Water temp. sensor connector
- Water temp. sender gauge connector
- Cold start injector time switch connector
- Distributor connector
- Igniter connector
- Noise filter connector
- Injector connectors
- VSV connector
- Knock sensor connector
- (California Specification Vehicles) EGR gas temp. sensor connector
- Ground strap from intake manifold
- Starter connector (terminal 50)
- Transmission connectors
- A/C compressor connector
- Check connector Connector from relay block
25. INSTALL AIR INTAKE CHAMBER






(a) Position a new gasket on the intake manifold.
(b) Connect the cold start injector connector.
(c) Install the intake chamber and vacuum transmitting pipes with the two nuts and five bolts.
Torque: 180kg-cm (13 ft-lb, 18 N.m)
(d) Connect the vacuum transmitting pipe to the No.2 fuel pipe stay with the bolt.
(e) Connect the engine wire to the clamps of the intake chamber.
(f) Install the cold start injector tube.
26. INSTALL COLD START INJECTOR TUBE






Install the cold start injector tube to the delivery pipe and cold start injector with new gaskets and union bolts.
Torque:
Delivery pipe side 300 kg-cm (22 ft-lb, 29 N.m)
Cold start injector side 180 kg-cm (13 ft-lb, 18 N.m)
27. CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY
28. CHECK FOR FUEL LEAKAGE
Torque: To delivery pipe 300 kg-cm (22 ft-lb, 29 N.m) To cold start injector 180 kg-cm (13 ft-lb, 18 N.m)
(g) Install the EGR vacuum modulator to the bracket.






(h) Install the EGR pipe mounting bolts.






(i) Install the manifold stay with the two bolts.
(j) Connect the following hoses:
- No.3 water by-pass hose to throttle body
- No.1 water by-pass hose to ISC valve
- PS air hose
- Pressure regulator hose
- EGR hoses to throttle body and vacuum transmitting pipe
- Vacuum transmitting pipe hose to air intake chamber
- BVSV hose to throttle body
(k) Connect the following connectors:
- ISC valve connector
- Throttle position sensor connector