Cylinder Head Installation

INSTALLATION OF CYLINDER HEAD
1. INSTALL CYLINDER HEAD
(a) Apply seal packing to the two locations shown. Seal packing: Part NO.08826-00080 or equivalent

(b) Place a new cylinder head gasket on the cylinder block.

CAUTION: Be careful of the installation direction.

(c) Place the cylinder head on the cylinder head gasket, and connect the No.5 water by-pass hose to the union.
(d) Apply a light coat of the engine oil on the threads and under the cylinder head bolts.

(e) Using SST, install and uniformily tighten the fourteen cylinder head bolts in several passes and in the sequence shown. SST 09043-38100
Torque: 800 kg-cm (58 ft-lb, 78 N.m)
2. INSTALL CAMSHAFT TIMING PULLEYS AND TIMING BELT
3. INSTALL SPARK PLUGS

4. INSTALL CYLINDER HEAD COVERS
(a) Using SST, install the No.3 cylinder head cover and heater hose clamp. SST 09923-00010
Torque: 180 kg-cm (13 ft-lb, 18 N.m)

(b) Apply seal packing to the cylinder head as shown in the figure. Seal packing: Part No.08826-00080 or equivalent
(c) Install the No. 1 and No.2 cylinder head cover.
Torque: 25 kg-cm (22 in.- lb, 2.5 N.m)

(d) Install the heater hose clamp.
(e) Install the accelerator link.

5. INSTALL WATER OUTLET HOUSING
(a) Install a new gasket and water outlet housing with the bolt and two nuts.
(b) Connect the No.6 water by-pass hose.

6. INSTALL EXHAUST MANIFOLD
(a) Face the new exhaust gasket so the protrusion is facing the rear and install on the cylinder head.

(b) Install the exhaust manifold with the seven nuts.
Torque: 400 kg-cm (29 ft-lb, 39 N.m)

(d) (7M-GTE) Install the heat insulators with the five bolts.
7. (7M-GTE) INSTALL TURBOCHARGER
8. (7M-GE) INSTALL OIL DIPSTICK
9. (7M-GE) INSTALL DISTRIBUTOR AND HIGH-TENSION CORDS

10. (7M-GTE) INSTALL AUXILIARY AIR PIPE

11. INSTALL NO.3 FUEL PIPE
(a) Install a new gasket, No.3 fuel pipe, another gasket and union bolt to the pressure regulator.
Torque: 250 kg-cm (18 ft-lb 25 N.m)
(b) Install the No.3 fuel pipe to the delivery pipe with the bolt.
(c) Connect the fuel hose to fuel support.

12. INSTALL No.1 FUEL PIPE AND PULSATION DAMPER
(a) Install a new gasket, No.1 fuel pipe, another gasket and pulsation damper to the delivery pipe.
(b) Install the No.1 fuel pipe and VSV to the intake manifold.
(c) Connect the No.1 fuel pipe to fuel support.
13. INSTALL ENGINE WIRE
(a) Install the engine wire to the four clamps.
(b) Connect following wires:
- Transmission connectors
- Starter connector(Terminal 50)
- Main relay connector
- Noise filter connector
(7M-GE) Ignition coil connector
(7M-GTE) Igniter connectors
- Solenoid resister connector
- Check connector
- Ground strap to intake manifold
- Knock sensor connector
- Three VSV connectors
- Injector connectors
- (7M-GE)
- Distributor connector
- Cold start injector time switch connector
- Water temp. sender gauge connector
- Water temp. sensor connector
- Oil pressure sender gauge connector
- Oxygen sensor connector
14. (7M-GTE) INSTALL IGNITION COIL WITH BRACKET
15. INSTALL AIR INTAKE CHAMBER WITH CONNECTOR
(a) Position a new gasket on the intake manifold.
(b) (7M-GTE) Connect the cold start injector connector.

(c) Install the intake chamber with connector and vacuum transmitting pipes with the two nuts and five bolts.
Torque: 180 kg-cm (13 ft-lb, 18 N.m)
(d) Connect the engine wire to the clamps of the intake chamber.

(e) Install new gaskets and cold start injector tube.
Torque: To delivery pipe 300 kg-cm (22 ft-lb, 29 N.m)
To cold start injector 180 kg-cm (13 ft-lb, 18 N.m)
(f) Install the EGR vacuum modulator to the bracket.

(g) (7M-GE) Install the air intake connector bracket mounting bolts.

(h) (7M-GE) Install the throttle body bracket.

(i) (7M-GTE) Install the ISC pipe and connect the hoses.

(j) Install the EGR pipe mounting bolts.
(k) Install the manifold stay mounting bolt.
(l) Connect following hoses:
(7M-GE)
- No.3 water by-pass hose to throttle body
(7M-GTE)
- No.3 water by-pass hose to water by-pass pipe
- No.1 water by-pass hose to union of cylinder block
(7M-GTE)
- Auxiliary air pipe hose to vacuum transmiting pipe
(m) Connect following hoses:
(7M-GE)
- Diaphragm hose
- VSV hoses (for FPU)
- PS air hose
- Pressure regulator hose
- Vacuum transmitting pipe hose to intake chamber
- EGR hoses to throttle body and vacuum transmitting pipe
- BVSV hose to throttle body
(n) Connect following wires:
- ISC valve connector
- Throttle position sensor connector
- (7M-GE) Cold start injector connector
(0) Install the PCV pipe.
16. (7M-GTE) INSTALL CAM POSITION SENSOR

17. INSTALL PS RESERVOIR TANK Install the PS reservoir tank with bracket.
18. INSTALL ALTERNATOR AND ADJUSTING BAR
(a) Install the alternator and adjusting bar.
(b) Install the drive belt.
(C) Connect the NO.3 PCV pipe.

19. CONNECT HEATER INLET HOSE
20. INSTALL RADIATOR INLET HOSE
21. CONNECT FOLLOWING HOSES:
(a) Charcoal canister hose
(b) Cruise control vacuum hose
(c) Brake booster hose

22. (7M-GE) INSTALL NO.1 AIR CLEANER HOSE WITH INTAKE AIR CONNECTOR PIPE

(7M-GTE) INSTALL NO.4 AIR CLEANER PIPE WITH NO.1 AND NO.2 AIR CLEANER HOSE
23. CONNECT GROUND STRAP TO ENGINE REAR SIDE
24. CONNECT FOLLOWING CABLES:
(a) (A/T) Throttle cable
(b) Accelerator cable
(c) Cruise control cable
25. CONNECT EXHAUST PIPE TO EXHAUST MANIFOLD
26. FILL WITH COOLANT
27. CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY
28. START ENGINE Warm up the engine and check for leaks.
29. PERFORM ENGINE ADJUSTMENT
Recheck the ignition timing.
30. ROAD TEST
Road test vehicle.
31. RECHECK COOLANT AND ENGINE OIL LEVEL