Cylinder Head - Installation

1. Install no. 2 cylinder head gasket

2. Install cylinder head gasket

3. Install cylinder head sub-assembly lh

4. Install cylinder head sub-assembly

5. Install front exhaust pipe

6. Install rear timing belt plate lh

7. Install no. 2 rear timing belt plate lh

8. Install rear timing belt plate rh

9. Install no. 2 rear timing belt plate rh

10. Install water by-pass joint rr

11. Install no. 2 air switching valve

12. Install water by-pass joint fr

13. Install water inlet housing

14. Install water by-pass pipe sub-assembly

15. Install intake manifold assembly

16. Install oil level gage guide

17. Install transmission oil filler tube sub-assembly

18. Install camshaft (for lh side)

19. Install camshaft (for rh side)

20. Install timing belt

​

1. Place a new cylinder head gasket in position on the cylinder block.

   HINT:

   A mark is placed on the rear side of the cylinder head gasket to distinguish the LH and RH banks, a "2R" mark for the RH bank and a "2L" mark for the LH bank.

   NOTICE:

   Be careful of the installation direction.

2. Place the cylinder head in position on the cylinder head gasket.

1. Place a new cylinder head gasket in position on the cylinder block.

   HINT:

   A mark is placed on the rear side of the cylinder head gasket to distinguish the LH and RH banks, a "2R" mark for the RH bank and a "2L" mark for the LH bank.

   NOTICE:

   Be careful of the installation direction.

2. Place the cylinder head in position on the cylinder head gasket.

1. Check that the timing mark of the crankshaft timing pulley is in the position shown in the illustration, and that the piston is below the TDC of compression.

2. Install the cylinder head with the exhaust manifold to the cylinder block.

   HINT:

   1. The cylinder head bolts are tightened in 2 progressive steps.
      
   2. If any cylinder head bolt is broken or deformed, replace it.
      

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

4. Install the plate washer to the cylinder head bolt.

5. Install and uniformly tighten the 10 cylinder head bolts, and plate washers, in the order shown in the illustration.

   Torque:

   40 N*m{408 kgf*cm, 30 ft.*lbf}

   If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt.
   

   NOTICE:

   Do not drop the plate washer for the cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan.

6. Mark the front of the cylinder head bolt head with paint.

7. Retighten the cylinder head bolts by 90° in the order shown.

8. Retighten the cylinder head bolts by an additional 90°.

9. Check that the painted mark is now at a 180° angle to front.

1. Check that the timing mark of the crankshaft timing pulley is in the position shown in the illustration, and that the piston is below the TDC of compression.

2. Install the cylinder head with the exhaust manifold to the cylinder block.

   HINT:

   1. The cylinder head bolts are tightened in 2 progressive steps.
      
   2. If any cylinder head bolt is broken or deformed, replace it.
      

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

4. Install the plate washer to the cylinder head bolt.

5. Install and uniformly tighten the 10 cylinder head bolts, and plate washers, in the order shown in the illustration.

   Torque:

   40 N*m{408 kgf*cm, 30 ft.*lbf}

   If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt.
   

   NOTICE:

   Do not drop the plate washer for the cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan.

6. Mark the front of the cylinder head bolt head with paint.

7. Retighten the cylinder head bolts by 90° in the order shown.

8. Retighten the cylinder head bolts by an additional 90°.

9. Check that the painted mark is now at a 180° angle to front.

1. Place a new gasket to the front exhaust pipe.

2. Install the 2 nuts and front exhaust pipe.

   Torque:

   62 N*m{632 kgf*cm, 46 ft.*lbf}

1. Install the bolt and rear timing belt plate LH.

   Torque:

   7.5 N*m{80 kgf*cm, 66 ft.*lbf}

1. Install the 2 bolts and No. 2 rear timing belt plate LH.

   Torque:

   7.5 N*m{80 kgf*cm, 66 ft.*lbf}

1. Install the timing belt plate with the bolt and stud bolt.

   Torque:

   7.5 N*m{80 kgf*cm, 66 ft.*lbf}

1. Install the timing belt plate with the 2 bolts.

   Torque:

   7.5 N*m{80 kgf*cm, 66 ft.*lbf}

1. With the flat-bottom of each new gasket facing downward as shown in the illustration, install the 2 gaskets to the engine rear side.

2. Install the water by-pass joint with the 4 nuts. Alternately tighten the nuts.

   Torque:

   18 N*m{185 kgf*cm, 13 ft.*lbf}

1. Install 2 new gaskets and the 2 No. 2 air switching valves with the 4 bolts to the water by-pass joint rear.

   Torque:

   10 N*m{102 kgf*cm, 7 ft.*lbf}

2. Connect the 2 vacuum hoses to the No. 2 air switching valves.

1. With the flat-bottom of each new gasket facing downward as shown in the illustration, install the 2 gaskets to the engine front side.

2. Install the water by-pass joint with the 4 nuts. Alternately tighten the nuts.

   Torque:

   18 N*m{185 kgf*cm, 13 ft.*lbf}

1. Install the water inlet with the 3 nuts.

   Torque:

   19 N*m{195 kgf*cm, 14 ft.*lbf}

1. Install a new O-ring to the water by-pass pipe.

2. Apply soapy water to the O-ring.

3. Push in the water by-pass pipe end into the pipe hole of the water pump.

4. Install the water by-pass pipe with the bolt.

   Torque:

   18 N*m{185 kgf*cm, 13 ft.*lbf}

1. Place 2 new gaskets on the intake manifold.

2. Place the intake manifold on the cylinder heads.

3. Install and uniformly tighten the 6 bolts and 4 nuts in several steps.

   Torque:

   18 N*m{185 kgf*cm, 13 ft.*lbf}

4. Install the V-bank cover bracket to the intake manifold.

   Torque:

   7.5 N*m{76 kgf*cm, 66 in.*lbf}

5. Install the wire bracket to the intake manifold with the bolt.

   Torque:

   7.5 N*m{76 kgf*cm, 66 in.*lbf}

6. Connect the engine wire to the engine hanger and wire bracket.

7. Connect the wire protector to the intake manifold and cylinder heads with the bolt and nut.

8. Install the 2 ground cables with the 2 bolts to the RH and LH cylinder heads.

9. Connect the 2 water by-pass hoses to the throttle body.

10. Connect the 2 wire clamps to the wire clamp bracket on the RH delivery pipe.

1. Install a new O-ring to the oil level gauge guide.

2. Install the oil level gauge guide with the bolt.

   Torque:

   15 N*m{155 kgf*cm, 11 ft.*lbf}

1. Install the transmission oil filler tube sub-assembly with the bolt.

   Torque:

   12 N*m{122 kgf*cm, 9 ft.*lbf}

NOTICE:

1. As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged. To avoid this, the following steps should be carried out.
   
2. Having the crankshaft pulley at a wrong angle can cause the piston head and valve head to come into contact with each other when removing the camshaft. Always set the crankshaft pulley at the correct angle as shown in the illustration.
   

1. Apply MP grease to the thrust portions of the camshafts.

2. Align the timing marks (2-dot marks) of the camshaft drive and driven main gears, and place the 2 camshafts.

3. Apply seal packing to the camshaft housing plug.

   1. Remove the old packing (FIPG) material.
      
   2. Apply seal packing to the housing plug.
      

   Seal packing:

   Part No. 08826-00080 or equivalent
   

4. Install the camshaft housing plug and oil control valve filter to the cylinder head as shown in the illustration.

   NOTICE:

   Be careful of the installation direction.

5. Apply seal packing to the front bearing cap.

   1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the bearing cap and cylinder head.
      Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and groove.
      Thoroughly clean all components to remove all the loose material.
      Using a non-residue solvent, clean both sealing surfaces.
      
   2. Apply seal packing to the bearing cap as shown in the illustration.
      Use a nozzle that has been cut to 1.5 to 2.0 mm (0.059 to 0.079 in.) opening.
      Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.
      Immediately remove the nozzle from the tube and reinstall the cap.
      

   Seal packing:

   Part No. 08826-00080 or equivalent
   

   NOTICE:

   Do not apply seal packing to the front bearing cap grooves.

6. Install the front bearing cap.

   HINT:

   The thrust position of the camshaft will be determined after installing the front bearing cap.

7. Install the other bearing cap in the order shown with the arrow mark facing forward.

8. Push in the camshaft setting oil seal.

9. Install a new seal washer to the bearing cap bolt (A and B).

10. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts (D and E).

11. Install the camshafts of the LH bank.

    NOTICE:

    Do not apply engine oil under the heads of the bearing cap bolts (A), (B) and (C).

    HINT:

    Each bolt length is as follows:

    94 mm (3.70 in.) for A with seal washer

    72 mm (2.83 in.) for B with seal washer

    25 mm (0.98 in.) for C

    55 mm (2.17 in.) for D

    40 mm (1.57 in.) for E

12. Install the oil feed pipe and the 22 bearing cap bolts as shown in the illustration.

13. Uniformly tighten the 22 bearing cap bolts in several steps, in the order shown in the illustration.

    Torque:

    For bolt C:

    7.5 N*m{76 kgf*cm, 66 in.*lbf}

    For others:

    16 N*m{163 kgf*cm, 12 ft.*lbf}

14. Bring the service bolt installed in the driven sub-gear upward by turning the hexagonal portion of the camshaft with a wrench.

15. Remove the service bolt.

NOTICE:

1. As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged. To avoid this, the following steps should be carried out.
   
2. Having the crankshaft pulley at a wrong angle can cause the piston head and valve head to come into contact with each other when installing the camshaft. Be sure to set the crankshaft pulley at the correct angle as shown in the illustration.
   

1. Crankshaft pulley
   

1. Apply engine oil to the thrust portion of the intake and exhaust camshafts.

2. Align the timing marks (1-dot mark) of the camshaft drive and driven main gears, and place the 2 camshafts.

3. Set the timing marks (1-dot mark) of the camshaft drive and driven main gears at approx. 10° angle.

4. Apply seal packing to the camshaft housing plug.

   1. Remove the old packing (FIPG) material.
      
   2. Apply seal packing to the housing plug.
      

   Seal packing:

   Part No. 08826-00080 or equivalent
   

5. Install the camshaft housing plug and oil control valve filter to the cylinder head as shown in the illustration.

   NOTICE:

   Be careful of the installation direction.

6. Apply seal packing to the front bearing cap.

   1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the bearing cap and cylinder head.
      Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and groove.
      Thoroughly clean all components to remove all the loose material.
      Using a non-residue solvent, clean both sealing surfaces.
      
   2. Apply seal packing to the bearing cap as shown in the illustration.
      Use a nozzle that has been cut to 1.5 to 2.0 mm (0.059 to 0.079 in.) opening.
      Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.
      Immediately remove the nozzle from the tube and reinstall the cap.
      

   Seal packing:

   Part No. 08826-00080 or equivalent
   

   NOTICE:

   Do not apply seal packing to the front bearing cap grooves.

7. Install the front bearing cap.

   HINT:

   The thrust position of the camshaft will be determined after installing the front bearing cap.

8. Install the other bearing caps in the order shown with the arrow mark facing forward.

9. Push in the camshaft setting oil seal.

10. Install new seal washers to the bearing cap bolts (A and B).

11. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts (D and E).

    NOTICE:

    Do not apply engine oil under the heads of the bearing cap bolts (A), (B) and (C).

    HINT:

    Each bolt length is as follows:

    94 mm (3.70 in.) for A with seal washer

    72 mm (2.83 in.) for B with seal washer

    25 mm (0.98 in.) for C

    55 mm (2.17 in.) for D

    40 mm (1.57 in.) for E

12. Install the oil feed pipe and the 22 bearing cap bolts as shown in the illustration.

13. Uniformly tighten the 22 bearing cap bolts in several steps, in the order shown in the illustration.

    Torque:

    For bolt C:

    7.5 N*m{76 kgf*cm, 66 in.*lbf}

    For others:

    16 N*m{163 kgf*cm, 12 ft.*lbf}

14. Bring the service bolt installed in the driven sub-gear upward by turning the hexagonal portion of the camshaft with a wrench.

15. Remove the service bolt.

HINT:

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