Reassembly

CYLINDER HEAD

COMPONENTS:

REASSEMBLY

1. INSTALL RING W/HEAD PIN
a. Using a plastic-faced hammer, tap in a new ring pin to the specified protrusion height (RH cylinder).
Protrusion height: 3 mm (0.12 inch)

2. INSTALL RING PIN
a. Using a plastic-faced hammer, tap in a new ring pin to the specified protrusion height (LH cylinder).
Protrusion height: 3 mm (0.12 inch)
3. INSTALL SPARK PLUG TUBE

a. Using paint, mark the standard position from the edge.
Standard protrusion height: 42.4 to 43.4 mm (1.669 to 1.709 inch)

HINT: Use either end of the spark plug tube.

b. Apply adhesive to the spark plug tube where it will be pressed into the cylinder head.
Adhesive: Part No. 08833-00070 THREE BOND 1324 or equivalent

NOTICE:
^ Install the spark plug tube within 3 minutes after applying adhesive.
^ Do not deform the spark plug tube.
^ Do not expose the seal to coolant within 1 hour after installing.

c. Using a press and wooden block, install the spark plug tube to the required protrusion height.

NOTICE: Be careful not to drip the adhesive.

4. INSTALL PCV PIPE
a. Using a wooden block and hammer, tap in 2 new PCV pipes until its top edge is flush with the cylinder head edge (RH cylinder).

NOTICE: Be careful not to damage the cylinder head edge.

5. INSTALL STUD BOLT

a. Install the stud bolts on the intake side (RH cylinder).
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)

b. Install the stud bolts on the intake side (LH cylinder).
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
6. INSTALL STUD BOLT
a. Install the stud bolts on the exhaust side.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
7. INSTALL VALVE STEM OIL O SEAL OR RING

a. Apply a light coat of engine oil on the valve stem.

NOTICE: Pay much attention assembling the oil seal for intake and exhaust. Assembling the wrong one may cause an improper installation.

HINT: The intake valve oil seal is light brown and the exhaust valve oil seal is gray.

b. Using SST, push in a new oil seal.
SST 09201-41020

NOTICE: Failure to use SST will cause the seal to be damaged or improperly seated.

8. INSTALL INTAKE VALVE

a. Install the valve, spring seat, valve spring, and spring retainer.

NOTICE: Install the same part in the same combination to the original locations.

b. Using SST, compress the valve spring and place the 2 keepers around the valve stem.
SST 09202-70020 (09202-00010)

a. Install the valve, spring seat, valve spring, and spring retainer.

NOTICE: Install the same parts in the same combination to the original locations.

b. Using SST, compress the valve spring and place the 2 keepers around the valve stem.
SST 09202-70020 (09202-00010)

c. Using a plastic-faced hammer and a discarded valve (the tip is wrapped with tape), lightly tap the installed valve to fit into place.

NOTICE: Be careful not to damage the installed valve stem tip.

10. INSTALL VALVE LIFTER
a. Apply a light coat of engine oil on the valve lifter.

NOTICE: Install the same part in the same combination to the original locations.

b. Install the valve lifter.
c. Check that the valve lifter rotates smoothly by hand.
11. INSTALL SEMICIRCULAR PLUG

a. Remove any old seal packing (FIPG) material.
b. Apply seal packing to the semi-circular plug grooves.
Seal packing: Part No. 08826-00080 or equivalent

c. Install the 2 semi-circular plugs to the cylinder heads.

NOTICE:
^ Install the plugs so that it is flush with the top of the cylinder head.
^ Install the semi-circular plugs within 3 minutes after applying seal packing.
^ Do not expose the seal to engine oil within 2 hours after installing.

12. INSTALL W/HEAD STRAIGHT SCREW PLUG NO. 1
a. Using a straight hexagon wrench 14, install 2 new gaskets and the 2 screw plugs (RH cylinder).
Torque: 44 Nm (449 kgf-cm, 32 ft. lbs.)
13. INSTALL W/HEAD STRAIGHT SCREW PLUG No. 2
a. Using a straight hexagon wrench 14, install 2 new gaskets and the 2 screw plugs (LH cylinder).
Torque: 44 Nm (449 kgf-cm, 32 ft. lbs.)

INSTALLATION

1. INSTALL CYLINDER HEAD GASKET
a. Place a new cylinder head gasket on the cylinder block with the R mark upward.

NOTICE:
^ Remove any oil from the contact surface.
^ Be careful to install of the installing orientation.
^ Place the cylinder head on the gasket carefully in order not to damage the gasket at the bottom part of the head.

2. INSTALL CYLINDER HEAD GASKET No. 2
a. Place a new cylinder head gasket on the cylinder block with the L mark upward.

NOTICE:
^ Remove any oil from the contact surface.
^ Be careful to install of the installing orientation
^ Place the cylinder head on the gasket carefully in order not to damage the gasket at the bottom part of the head.

3. INSTALL CYLINDER HEAD SUB-ASSEMBLY

NOTICE: The cylinder head bolts are tightened in 2 successive steps.

a. Apply a light coat of engine oil to the threads of the cylinder head bolts.
b. Install the plate washers to the cylinder head bolts.

c. Using several steps, install and tighten the 8 cylinder head bolts uniformly in the sequence shown in the illustration (procedure A).
Torque: 54 Nm (550 kgf-cm, 40 ft. lbs.)

d. Mark the front side of each cylinder head bolt head with paint as shown in the illustration.
e. Retighten the cylinder head bolts by 90° in the same sequence as procedure A.
f. Check that each painted mark is now at 90° angle to the front.

g. Using a socket hexagon wrench 8, install the hexagon bolt.
Torque: 19 Nm (189 kgf-cm, 14 ft. lbs.)
h. Connect the engine wire harness clamp with the nut.
Torque: 8.4 Nm (85 kgf-cm, 74 inch lbs.)
4. INSTALL CYLINDER HEAD LH

NOTICE: The cylinder head bolts are tightened in 2 successive steps.

a. Apply a light coat of engine oil on the threads of the cylinder head bolts.
b. Install the plate washer to the cylinder head bolt.

c. Using several steps, install and tighten the 8 cylinder head bolts uniformly in the sequence shown in the illustration (Procedure B).
Torque: 54 Nm (550 kgf-cm, 40 ft. lbs.)

d. Mark the front side of each cylinder head bolt head with paint as shown in the illustration.
e. Retighten the cylinder head bolts by 90° in the same sequence as procedure B.
f. Check that each painted mark is now at 90° angle to the front.

g. Using a socket hexagon wrench 8, install the hexagon bolt.
Torque: 19 Nm (189 kgf-cm, 14 ft. lbs.)
h. Install the bolt holding the water inlet to the cylinder head. (TMMWV MADE)
Torque: 20 Nm (199 kgf-cm, 14 ft. lbs.)
i. Install the wire harness clamp bracket with the bolt.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
j. Connect the ground cable with the bolts.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
5. INSTALL No. 2 CAMSHAFT
6. INSTALL CAMSHAFT
7. INSTALL NO. 4 CAMSHAFT SUB-ASSEMBLY
8. INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY
9. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
10. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
11. INSTALL IGNITION COIL ASSEMBLY
12. INSTALL WATER INLET PIPE
a. Install the water inlet pipe (TMC made).

13. INSTALL OIL LEVEL GAGE GUIDE
a. Install a new O-ring to the oil level gage guide.
b. Apply soapy water to the O-ring.
c. Push in the oil level gage guide end into the guide hole of the cylinder block.
d. Install the oil level gage guide with the bolt.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
e. Install the oil level gage.

14. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY
a. Install a new gasket and the exhaust manifold RH with the 6 nuts. Using several steps, tighten the nuts uniformly in the sequence shown in the illustration.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
b. Retighten nuts 1 and 2 shown in the illustration.
15. INSTALL MANIFOLD STAY
Torque: 34 Nm (347 kgf-cm, 25 ft. lbs.)
16. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 1
Torque: 8.5 Nm (87 kgf-cm, 75 inch lbs.)
17. INSTALL EXHAUST PIPE SUB-ASSEMBLY FRONT NO. 3

18. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY No. 2
a. Install a new gasket and the exhaust manifold converter No. 2 with the 6 nuts and bolt. Using several steps, tighten the nuts uniformly in the sequence in the illustration.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
b. Retighten nuts 1 and 2 shown in the illustration.
19. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 2
Torque: 8.5 Nm (87 kgf-cm, 75 inch lbs.)
20. INSTALL MANIFOLD CONVERTER INSULATOR NO. 3
Torque: 8.5 Nm (87 kgf-cm, 75 inch lbs.)
21. INSTALL EXHAUST PIPE ASSEMBLY FRONT
22. INSTALL PROPELLER SHAFT (for 4WD)
23. INSTALL VANE PUMP ASSEMBLY
24. INSTALL TIMING BELT NO. 3 COVER
25. INSTALL CAMSHAFT TIMING PULLEY
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
26. INSTALL TIMING BELT IDLER SUB-ASSEMBLY No. 2
27. INSPECT TIMING BELT
28. INSTALL TIMING BELT
29. INSTALL CHAIN TENSIONER ASSEMBLY NO. 1
30. INSTALL TIMING BELT GUIDE No. 2
31. INSTALL ENGINE MOUNTING BRACKET RH
32. INSTALL TIMING BELT No. 2 COVER
33. INSTALL TIMING BELT NO. 1 COVER
34. INSTALL CRANKSHAFT PULLEY
SST 09213-54015 (91651-60855), 09330-00021
35. INSTALL GENERATOR BRACKET No. 2
36. INSTALL ENGINE MOUNTING STAY No. 2 RH
37. INSTALL ENGINE MOVING CONTROL ROD
38. INSTALL VANE PUMP V BELT
39. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO. 1
40. INSTALL DRIVE BELT DEFLECTION AND TENSION
41. INSTALL WATER OUTLET
a. Install 2 new gaskets to the 2 cylinder heads.
b. Install the water outlet together with water by-pass hose No. 1 and unlock the hose clamp.
c. Tighten the 2 bolts, 2 nuts and 2 washers.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
d. Install the clamp.
e. Connect the engine coolant temperature sensor connector.
f. Connect the radiator hose inlet.

42. INSTALL INTAKE MANIFOLD
a. Install the intake manifold with the 9 bolts, 2 nuts and 2 washers. Using several steps, tighten the bolts and nuts uniformly in the sequence shown in the illustration.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
b. Retighten the water outlet mounting bolts and nuts.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
c. Install the ground cable with the nut.
Torque: 8.4 Nm (86 kgf-cm, 74 inch lbs.)
d. Connect the heater inlet water hose.
43. CONNECT FUEL PIPE SUB-ASSEMBLY NO. 1
44. INSTALL INTAKE AIR SURGE TANK
45. INSTALL EMISSION CONTROL VALVE SET
46. INSTALL AIR CLEANER CASE
47. INSTALL AIR CLEANER INLET No. 2
48. INSTALL AIR CLEANER CAP SUB-ASSEMBLY
49. CONNECT VACUUM HOSE
50. INSTALL V-BANK COVER SUB-ASSEMBLY
51. INSTALL COWL TOP PANEL SUB-ASSEMBLY OUTER
52. INSTALL WINDSHIELD WIPER LINK ASSEMBLY
53. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
54. INSTALL FR WIPER ARM LH
55. INSTALL FR WIPER ARM RH
56. INSTALL FRONT WHEEL RH
57. ADD ENGINE OIL
58. ADD ENGINE COOLANT
59. CHECK FOR ENGINE OIL LEAKS
60. CHECK FOR ENGINE COOLANT LEAKAGE
61. INSPECT FUEL LEAKAGE
62. CHECK FOR EXHAUST GAS LEAKAGE
63. INSPECT IGNITION TIMING
SST 09843-18040
64. INSPECT ENGINE IDLE SPEED
SST 09843-18040
65. INSPECT COMPRESSION
SST 09992-00500
66. INSPECT CO/HC