Installation
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INSTALLATION
HINT:
^ Thoroughly clean all parts to be assembled.
^ Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
^ Replace all gaskets and oil seals with new ones.
1. PLACE CYLINDER HEAD ON CYLINDER BLOCK
a) Place a new cylinder head gasket on the cylinder block surface with the Lod No. stamp upward.
NOTICE: Be careful of the installation direction.
b) Place the cylinder head quietly in order not to damage the gasket with the bottom part of the head.
2. INSTALL CYLINDER HEAD BOLTS
HINT:
^ The cylinder head bolts are tightened in 3 progressive steps (steps b) and (d)).
^ If any cylinder head bolt is broken or deformed, replace it.
a) Apply a light coat if engine oil on the threads and under the heads of the cylinder head bolts.
b) Using a 8 mm bi-hexagon wrench, install and uniformly tighten the 10 cylinder head bolts and plate washers, in several passes, in the sequence shown.
Torque: 29.4 Nm (300 kgf-cm, 22 ft. lbs.)
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 with paint.
d) Retighten the cylinder head bolts by 90° and 90° in the numerical order shown.
e) Check that the paint mark is now at a 180° angle to the front.
f) Install the bolt holding the water bypass pipe to the cylinder head
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
g) Connect the upper radiator hose to the water hose unions.
h) Connect the heater hose to the water hose unions.
3. INSTALL CAMSHAFTS
a) Place the 2 camshafts on the cylinder head with the No.1 cam lobes facing as shown the illustration.
b) Install the bearing caps in their proper locations.
HINT: No. 2 camshaft bearing cap has a number and front mark.
c) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
d) Install and uniformly tighten the 19 bearing cap bolts.
After tightening the No.1 camshaft bearing cap, tighten then in several passes, in the sequence shown.
Torque:
No. 1 23 Nm (235 kgf-cm, 17 ft. lbs.)
No. 2 12.7 Nm (130 kgf-cm, 10 ft. lbs.)
4. INSTALL VALVE TIMING CONTROLLER ASSEMBLY AND CAMSHAFT TIMING SPROCKET
a) Apply engine oil in the rage from the tip of the intake camshaft to 16 mm from that tip.
b) Align the timing mark on the value timing controller assembly with the knock pin, and install the value timing controller assembly to the camshaft.
NOTICE: Do not push valve timing controller assembly to the camshaft forcibly when installing it.
c) Align the knock pin hole in the camshaft timing sprocket with the knock pin of the camshaft, and install the sprocket to the camshaft.
d) Temporarily install the timing sprocket bolt.
e) Hold the hexagon head portion of the camshaft with a wrench, and install the bolt.
Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.)
5. CHECK AND ADJUST VALVE CLEARANCE
6. INSTALL CYLINDER HEAD COVER
7. INSTALL CAMSHAFT TIMING SPROCKETS
8. INSTALL OIL FILTER CAP
9. INSTALL PCV VALVE
10. INSTALL ECT SENSOR
11. INSTALL CAMSHAFT POSITION SENSOR
12. INSTALL TIMING CHAIN COVER
13. INSTALL INTAKE MANIFOLD
a) Install a new gasket, the intake manifold and 2 brackets with the 2 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.
Torque: 30 Nm (300 kgf-cm, 22 ft. lbs.)
b) Connect the EVAP hose for ORVR.
c) Connect the brake booster vacuum hose.
14. CONNECT ENGINE WIRE TO CYLINDER HEAD
a) Install the engine wire protector to the 2 brackets on the intake manifold with the 2 bolts.
b) Connect the ECT sensor connector.
c) Connect the camshaft position sensor connector.
d) Connect the oil control valve connector.
e) Connect the 4 injector connectors.
f) Connect the 2 ground wire.
15. INSTALL THROTTLE BODY
16. INSTALL PCV HOSES
17. INSTALL SPARK PLUGS
18. INSTALL IGNITION COILS
19. INSTALL EXHAUST MANIFOLD
a) Install a new gasket and the exhaust manifold with the 3 bolts 2 nuts. Uniformly tighten the nuts in several passes.
Torque: 27 Nm (275 kgf-cm, 20 ft. lbs.)
b) Install the upper heat insulator with the 4 bolts.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
20. INSTALL EXHAUST MANIFOLD STAY
Install the manifold stay with the 3 bolts. Alternately tighten the bolts.
Torque: 37 Nm (377 kgf-cm, 27 ft. lbs.)
21. CONNECT FRONT EXHAUST PIPE TO EXHAUST MANIFOLD
a) Place a new gasket to the exhaust manifold.
b) Install the 2 bolts and 2 springs holding the front exhaust pipe to the exhaust manifold.
Torque: 62 Nm (630 kgf-cm, 46 ft. lbs.)
22. CONNECT ACCELERATOR CABLE
23. INSTALL AIR CLEANER ASSEMBLY
24. INSTALL GENERATOR AND DRIVE BELT
25. INSTALL WATER FILLER
Install the water filler with the 2 bolts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
26. FILL WITH ENGINE COOLANT
27. START ENGINE AND CHECK FOR LEAKS
28. RECHECK ENGINE COOLANT LEVEL AND OIL LEVEL