Installation

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. INSTALL CYLINDER HEAD
a Place the cylinder head on the cylinder block.





1 Apply seal packing to the cylinder head gasket as shown in the illustration
Seal packing: Part No. 08826-00080 or equivalent
- Install a nozzle that has been cut to a 2.5 - 3.0 mm (0.10 - 0.12 inch) opening.

HINT: Avoid applying an excessive amount to the surface.

- Part must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied.
- Immediately remove nozzle from the tube and reinstall cap.





2 Place a new cylinder head gasket on the cylinder block surface with the lot No. upward.

NOTICE: Be careful of the installation direction.

3 Place the cylinder head quietly in order not to damage the gasket with the bottom part of the head.
b Install the cylinder head bolts.

HINT:
- The cylinder head bolts are tightened in 2 steps (steps (2) and (4))
- If any cylinder head bolt is broken or deformed, replace it.

1 Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.

Cylinder Head Bolt Torque Sequence:

2 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: 79 Nm (800 kgf-cm, 58 ft. lbs.)
If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt.





3 Mark the front of the cylinder head bolt with paint.
4 Retighten the cylinder head bolts 90° in the numerical order shown.
5 Check that the painted mark is now at a 90° angle to the front.
2. INSTALL CAMSHAFTS





a Install the lower camshaft bearing to the cylinder head.





b Align the bearing claw with the claw groove of No. 1 bearing cap, and push in the upper camshaft bearing.





c Place the 2 camshafts on the cylinder head with the No. 1 cam lobes facing as shown the illustration.





d Install the bearing caps in their proper locations.

HINT:
- Each of No. 3 camshaft bearing cap has a number and front mark.
- The No. 1 and No. 2 bearing caps has a front marks.

e Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.

Camshaft Bearing Cap Bolt Torque Sequence:

f Install and uniformly tighten the 20 bearing cap bolts in several passes, in the sequence shown.
Torque:
29.5 Nm (300 kgf-cm, 22 ft. lbs.) for No. 1 and No. 2
9 Nm (90 kgf-cm, 80 inch lbs.) for others





3. CHECK AND ADJUST VALVE CLEARANCE

NOTICE: Under the condition with the timing chain cover removed, in case of rotating the camshafts, make the position of the crankshaft rotated clockwise by about 45° from TDC/compression of No. 1 cylinder.

Turn the camshafts and position the cam lobe upward, and check and adjust the valve clearance.
4. INSTALL CAMSHAFT TIMING SPROCKET AND VVT TIMING SPROCKET
5. INSTALL TIMING CHAIN
6. INSTALL CAMSHAFT POSITION SENSOR
7. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE (OCV)
8. INSTALL OIL FILLER CAP





9. INSTALL INTAKE MANIFOLD AND THROTTLE BODY ASSEMBLY
a Install a new gasket to the intake manifold.
b Install intake manifold insulator.
c Install the intake manifold and throttle body assembly with the 5 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.
Torque: 30 Nm (305 kgf-cm, 22 ft. lbs.)
d Connect the engine wire harness to the clamp.
e Connect the 2 vacuum hoses to the intake manifold.
f Connect the 2 water hoses to the throttle body.
g Connect the IAC valve connector.
h Connect the throttle position sensor connector.
10. INSTALL PCV VALVE AND HOSES
a Install the PCV valve with the grommet.
b Install the PCV hoses.
11. CONNECT ENGINE WIRE
a Connect the noise filter.
b Connect the ETC sensor connector.
c Connect the camshaft position sensor connector.
d Connect the oil pressure switch connector and wire.
e Connect the crankshaft position sensor.
f Connect the OCV connector.
g Install the engine wire with the 2 bolts.
12. INSTALL HEAT INSULATORS TO EXHAUST MANIFOLD
a Temporary install the No. 1 and No. 2 exhaust manifold stays to the exhaust manifold with the 2 nuts.
b Install the No. 2 lower heat insulator to the exhaust manifold with the 4 bolts.
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)
c Install the No. 1 lower heat insulator to the exhaust manifold with the 3 bolts.
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)





13. INSTALL EXHAUST MANIFOLD ASSEMBLY
a Install a new gasket and the exhaust manifold with the 5 nuts.
Torque: 37 Nm (375 kgf-cm, 27 ft. lbs.)
b Install the 2 exhaust manifold stays with the 2 bolts.
Torque: 44 Nm (450 kgf-cm, 33 ft. lbs.)
c Tighten the 2 nuts holding the exhaust manifold stays to crank case.
Torque: 44 Nm (450 kgf-cm, 33 ft. lbs.)
d Install the 2 compression springs and 2 bolts holding the exhaust manifold and front exhaust pipe.
Torque: 43 Nm (439 kgf cm, 32 ft. lbs.)
e Install the upper heat insulator with the 3 bolts and nut.
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)
f Connect the 2 A/F sensor connectors.
g Connect the 2 heated oxygen sensor wires to the wire bracket.
14. INSTALL INJECTORS
15. INSTALL SPARK PLUGS
16. INSTALL IGNITION COILS
17. INSTALL PS VANE PUMP
18. INSTALL GENERATOR
19. INSTALL DRIVE BELT





20. INSTALL AIR CLEANER ASSEMBLY
a Connect the PCV hose to the cylinder head cover.
b Connect the CCV hose to the air cleaner.
c Connect the VSV connect for EVAP.
d Connect the 2 EVAP hoses to the VSV.
e Connect the MAP meter connector.
21. FILL WITH ENGINE OIL
22. FILL WITH ENGINE COOLANT
23. START ENGINE AND CHECK FOR LEAK
24. RECHECK ENGINE OIL AND COOLANT LEVEL
25. INSTALL RH ENGINE UNDER COVER