Installation
Part 1 Of 2:
Part 2 Of 2:
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 lot No. 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 2 steps (steps (b) and (d)).
- If any cylinder head bolt is broken or deformed, replace it.
a. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
b. Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 10 cylinder head bolts and plate washers in several passes, in the sequence shown.
Torque: 49 Nm (500 kgf-cm, 36 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 90° in the numerical order shown.
e. Check that the painted mark is now at a 90° angle to the front.
f. Install the bolt holding the water bypass pipe to the cylinder head.
Torque: 9 Nm (92 kgf-cm, 80 inch lbs.)
g. Connect the upper radiator hose to the water hose union.
h. Connect the heater hose to the water hose union.
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. 3 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 them in several passes, in the sequence shown.
Torque:
23 Nm (235 kgf-cm, 17 ft. lbs.) for No. 1
13 Nm (133 kgf-cm, 10 ft. lbs.) for No. 3
HINT:
Bearing cap No. 1 - Illustration No. 9
Bearing cap No. 3 - Illustrations 1 to 8
4. CHECK AND ADJUST VALVE CLEARANCE
5. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE
6. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE FILTER
7. INSTALL CAMSHAFT TIMING SPROCKET AND VVT TIMING SPROCKET
8. INSTALL TIMING CHAIN
9. INSTALL CAMSHAFT POSITION SENSOR
10. INSTALL OIL FILLER CAP
11. INSTALL INTAKE MANIFOLD AND THROTTLE BODY ASSEMBLY
a. Install a new gasket to the intake manifold.
b. Install the intake manifold and throttle body assembly with the 2 brackets, 4 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
c. Connect the 2 vacuum hoses to the intake manifold.
d. Connect the 2 water hoses to the throttle body.
12. INSTALL PCV VALVE AND HOSES
a. Install the PCV valve with the grommet.
b. Install the PCV hoses.
13. CONNECT ENGINE WIRE
a. Install the engine wire with the 2 bolts.
b. Install the 2 ground straps with the 2 bolts.
c. Connect the noise filter.
d. Connect the throttle position sensor connector.
e. SMT: Throttle control motor connector.
f. SMT: Accelerator position sensor connector.
g. M/T: Connect the IAC valve connector.
h. Connect the ECT sensor connector.
i. Connect the camshaft position sensor connector.
j. Connect the oil pressure switch connector and wire.
k. Connect the knock sensor connector.
l. Connect the crankshaft position sensor connector.
m. Connect the camshaft timing oil control valve connector.
n. Connect the heated oxygen sensor (bank 1 sensor 1) wire to the wire bracket.
14. INSTALL EXHAUST MANIFOLD
a. Install a new gasket and the exhaust manifold with the 5 nuts.
Torque: 37 Nm (377 kgf-cm, 27 ft. lbs.)
b. Install the 2 exhaust manifold stays with the 4 bolts.
Torque: 37 Nm (377 kgf-cm, 27 ft. lbs.)
c. Place the upper heat insulator on the exhaust manifold.
d. Install the 2 heated oxygen sensors.
Torque: 44 Nm (450 kgf-cm, 32 ft. lbs.)
e. Install the upper heat insulator with the 4 bolts.
f. Connect the 2 heated oxygen sensors.
15. INSTALL INJECTORS
16. INSTALL SPARK PLUGS
17. INSTALL IGNITION COILS
18. INSTALL GENERATOR
19. INSTALL ENGINE UNIT