Assembly

ASSEMBLY OF CYLINDER HEAD

NOTE:
- Thoroughly clean all parts to be assembled.
- Before installing the parts, apply new engine oil to all sliding and rotating surfaces.
- Replace all gaskets and oil seals with new ones.






1. INSTALL VALVES
(a) Insert the valves in the cylinder head valve guide bushing. Make sure the valves are installed in the correct order.






(b) Using SST, install new oil seals on the valve guide bushings. SST 09201-41020
(c) Install spring seats, springs and spring retainers.
(d) Using SST, compress the valve retainers and place two keepers around the valve stem. SST 09202-70010
(e) Tap the stem lightly to assure proper fit.






2. INSTALL VALVE LIFTERS WITH SHIMS
Make sure the valve lifters with their shims are installed in the correct order.






3. INSTALL CAMSHAFTS AND OIL SEALS
(a) Apply engine oil to the lip of a new oil seal.
(b) Install the oil seal to the camshaft.






(c) Coat all bearing journals with engine oil
(d) Place the camshafts on the cylinder head as shown in the figure.

NOTE: The exhaust camshaft has a distributor (7M GE) or cam position sensor (7M-GTE) drive gear.






(e) Apply seal packing to the areas indicated in the figure. Seal packing: Part NO.08826-00080 or equivalent

NOTE: Install the No.1 bearing cap immediately after applying the seal packing.






(f) Place bearing caps on each journal with the front marks pointing toward the front.






(g) Tighten each bearing cap bolt a little at a time and in the sequence shown in the figure.






(h) Using SST, drive in the camshaft oil seals. SST 09223-50010

NOTE: Be careful not to install the oil seal slantwise.






(i) Tighten the No.3 and No.7 bearing cap bolt a little at a time and in the sequence shown in the figure.
Torque: 200 kg-cm (14 ft-lb, 20 N.m)






(j) Torque each bearing cap bolt a little at a time and in the sequence shown in the figure.
Torque: 200 kg-cm (14 ft-lb, 20 N.m)
(k) Check the camshaft thrust clearance.






4. INSTALL EGR COOLER
Install a new gasket and EGR cooler with the eight bolts.
Torque: 140 kg-cm (10 ft-lb, 14 N.m)






5. INSTALL HEATER UNION
Install a new gasket, union, another gasket and union bolt to the cylinder head. Torque the union bolt.
Torque: 600 kg-cm (43 ft-lb, 59 N.m)
6. INSTALL NO.2 ENGINE HANGER AND GROUND STRAP Torque: 400 kg-cm (29 ft-lb, 39 N.m)






7. INSTALL INTAKE MANIFOLD
(a) Position a new gasket on the cylinder head.
(b) Install the intake manifold and VSV with the two nuts and seven bolts.
(c) Install the EGR valve with the two nuts.
(d) Torque the bolts and nuts.
Torque: 180 kg-cm (13 ft-lb, 18 N.m)






8. INSTALL DELIVERY PIPE WITH INJECTORS
(a) Install the six insulators into the injector hole of the cylinder head.
(b) Install the black rings on the upper portion of each the three spacers. Then install the spacers on the delivery pipe mounting hole of the cylinder head.






(c) Place the injectors together with the delivery pipe on the cylinder head.
(d) Make sure that the injectors rotate smoothly.






(e) Install the three thinner spacers and bolts. Torque the bolts.
Torque: 180 kg-cm (13 ft-lb, 18 N.m)
9. INSTALL ALTERNATOR BRACKET
Torque: 400 kg-cm (29 ft-lb, 39 N.m)
10. INSTALL NO.2 TIMING BELT COVER