Cylinder Head Installation

INSTALLATION OF CYLINDER HEAD
1. INSTALL CYLINDER HEAD
(a) Place a new cylinder head gasket on the cylinder block.

CAUTION: Be careful of the installation direction.

(b) Place the cylinder head on the cylinder head gasket.






2. TORQUE CYLINDER HEAD BOLTS

NOTE:
- The cylinder head bolts are tightened in three progressive steps.
- If any of the bolts break or deform, replace them.
(a) Apply a light coat of engine oil on the threads and under the cylinder head bolts.
(b) First, uniformly tighten the ten cylinder head bolts in several passes and in the sequence shown.
Torque: 300 kg-cm (22 ft-lb, 29 N.m)






(c) Second, uniformly tighten the ten cylinder head bolts in sequence shown.
Torque: 500 kg-cm (36 ft-lb, 49 N.m)
If any of the bolts do not meet the torque specification, replace the bolt.






(d) Third retighten the cylinder head bolts an additional 90° in order, as shown above left.
3. INSTALL CAMSHAFT TIMING PULLEY AND TIMING BELT






4. ADJUST VALVE CLEARANCE
(a) Turn the crankshaft pulley and align its groove with the "O" mark on the No.1 timing belt cover.
(b) Check that the rocker arm on No.1 cylinder are loose and the rockers on No.4 are tight. If not, turn the crankshaft one complete revolution and align the marks as above.






(c) Measure only those valves indicated.
Valve clearance (hot): 0.20 mm (0.008 in.)
(Reference)
Valve clearance (cold): 0.18 mm (0.007 in.)

NOTE: After installing the cylinder head, warm up the engine and adjust the valve clearance.






(d) Using a thickness gauge, measure the gap between the cam and rocker arm. Loosen the lock nut and turn the adjusting screw to the specified clearance. Hold the adjusting screw in position and tighten the lock nut.
(e) Recheck clearance. The thickness gauge should move with a very slight drag.






(f) Turn the crankshaft one revolution and adjust the other valves.

5. INSTALL WIRE HARNESS CLAMP BOLT TO INTAKE MANIFOLD






6. INSTALL INTAKE MANIFOLD STAY AND GROUND STRAP
Install the intake manifold stay and ground strap with the bolt and nuts.






7. CONNECT EXHAUST PIPE
(a) Install a new gasket to exhaust pipe.
(b) Connect the exhaust pipe to exhaust manifold with two new nuts.
Torque: 630 kg-cm (46 ft-lb, 62 N.m)






8. CONNECT WATER BY-PASS HOSE TO CARBURETOR






9. INSTALL EVAP VSV AND NO.2 COLD ENRICHMENT BREAKER VSV
10. CONNECT THE FOLLOWING HOSES:
(a) OVCV hose
(b) EVAP purge hoses
(c) PS air hoses
(d) Vacuum switch hoses
(e) (with A/C) VSV hoses
(f) (Federal and Canada) HAC hoses
11. CONNECT THE FOLLOWING WIRES:
(a) Solenoid valve wire
(b) Fuel heater and CMH wire
(c) VSV wire (for TP)
(d) EBCV wire
(e) VSV wire
(for EVAP and No.2 cold enrichment breaker system)
(f) Oxygen sensor wire
(g) Water temp. sender gauge wire
(h) Water temp. switch wire
(i) Distributor wire






12. CONNECT INTAKE MANIFOLD WATER HOSE TO INTAKE MANIFOLD
13. CONNECT WATER HOSE
14. CONNECT BRAKE BOOSTER HOSE TO INTAKE MANIFOLD
15. (Federal and Canada)
INSTALL AS HOSE AND VALVE
(Calif.) INSTALL AS HOSE
16. DISCONNECT FUEL HOSES TO FUEL PUMP
17. CONNECT HEATER INLET HOSE
18. (A/T) CONNECT THROTTLE CABLE
(a) Connect the throttle cable to the bracket.
(b) Adjust the throttle cable
19. CONNECT ACCELERATOR CABLE Automatic Transmission/Transaxle See Throttle Valve Cable/Linkage, A/T, Adjustments.
Connect the accelerator cable to the bracket.
20. CONNECT RADIATOR HOSES
21. (with A/C)
INSTALL IDLER PULLEY BRACKET






22. (w/PS)
INSTALL PS PUMP AND BRACKET
23. FILL WITH COOLANT Engine, Cooling and Exhaust See Coolant, Service and Repair.
24. INSTALL RH ENGINE UNDER COVER
25. CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY
26. START ENGINE
Warm up the engine and inspect leaks.
27. PERFORM ENGINE ADJUSTMENT
28. ROAD TEST
Road test the vehicle.