Cylinder Head - Installation

1. Install no. 2 cylinder head gasket

2. Install cylinder head lh

3. Install cylinder head gasket

4. Install cylinder head sub-assembly

5. Install camshafts (for bank 2)

6. Install no. 3 chain tensioner assembly

7. Install camshaft timing gears and no. 2 chain (for bank 2)

8. Install no. 1 chain vibration damper

9. Install no. 2 camshaft bearing

10. Install camshafts (for bank 1)

11. Install no. 2 chain tensioner assembly

12. Install camshaft timing gears and no. 2 chain (for bank 1)

13. Install water by-pass joint rr

14. Install intake manifold

15. Connect no. 2 fuel pipe sub-assembly

16. Connect no. 1 fuel pipe sub-assembly

17. Install exhaust manifold sub-assembly lh

18. Install no. 2 manifold stay

19. Install no. 2 exhaust front pipe assembly

20. Install exhaust manifold sub-assembly rh

21. Install manifold stay

22. Install exhaust pipe assembly front

23. Install transmission oil filler tube sub-assembly

24. Install no. 1 cool air inlet

25. Install chain sub-assembly

26. Add engine oil

27. Add engine coolant

28. Check for engine oil leakage

29. Check for engine coolant leakage

30. Check for fuel leakage

31. Check for exhaust gas leakage

32. Inspect engine idle speed

33. Inspect compression

34. Inspect co/hc

​

1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head and cylinder block.

2. Apply seal packing (diameter: 2.5 to 3 mm (0.098 to 0.118 in.)) to a new cylinder head gasket as shown in the illustration.

   Seal packing:

   Part No. 08826-00080 or equivalent
   

   NOTICE:

   Install the cylinder head within 3 minutes after applying seal packing. After installing it, the cylinder head bolts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied.

3. Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upper side facing upward.

   NOTICE:

   1. Be careful of the installation direction.
      
   2. Place the cylinder head carefully in order not to damage the gasket with the bottom part of the head.
      

1. Place the cylinder head on the cylinder head gasket.

2. Install the 8 cylinder head bolts.

   HINT:

   1. The cylinder head bolts are tightened in 2 successive steps (Procedures "A" and "B").
      
   2. If any cylinder head bolt is broken or deformed, replace it.
      
   
   

   1. Apply a light coat of engine oil to the threads of the cylinder head bolts.

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

   4. Using several steps, tighten each bolt uniformly with a 10 mm bi-hexagon wrench in the sequence as shown in the illustration (Procedure "A").

      Torque:

      36 N*m{367 kgf*cm, 27 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 washers into the cylinder head.

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

   7. Retighten the cylinder head bolts 180° as shown (Procedure "B").

   8. Check that the painted marks are now at 180° opposite to the engine front.

3. Install the 2 cylinder head bolts.
   

   1. Apply a light coat of engine oil to the threads of the cylinder head bolts.

   2. Using several steps, install and tighten the 2 cylinder head bolts uniformly in the sequence as shown in the illustration.

      Torque:

      30 N*m{306 kgf*cm, 22 ft.*lbf}

4. Install the ground cable with the bolt.

   Torque:

   8.0 N*m{82 kgf*cm, 71 in.*lbf}

1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head and cylinder block.

2. Apply seal packing (diameter: 2.5 to 3 mm (0.098 to 0.118 in.)) to a new cylinder head gasket as shown in the illustration.

   Seal packing:

   Part No. 08826-00080 or equivalent
   

   NOTICE:

   Install the cylinder head within 3 minutes after applying seal packing. After installing it, the cylinder head bolts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied.

3. Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upper side facing upward.

   NOTICE:

   1. Be careful of the installation direction.
      
   2. Place the cylinder head carefully in order not to damage the gasket with the bottom part of the head.
      

1. Place the cylinder head on the cylinder head gasket.

2. Install the 8 cylinder head bolts.

   HINT:

   1. The cylinder head bolts are tightened in 2 successive steps (Procedures "A" and "B").
      
   2. If any cylinder head bolt is broken or deformed, replace it.
      
   
   

   1. Apply a light coat of engine oil to the threads of the cylinder head bolts.

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

   4. Using several steps, tighten each bolt uniformly with a 10 mm bi-hexagon wrench in the sequence as shown in the illustration (Procedure "A").

      Torque:

      36 N*m{367 kgf*cm, 27 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 washers into the cylinder head.

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

   7. Retighten the cylinder head bolts 180° as shown (Procedure "B").

   8. Check that the painted marks are now at 180° opposite to the engine front.

3. Install the ground cables with the 2 bolts.

   Torque:

   8.0 N*m{82 kgf*cm, 71 in.*lbf}

NOTICE:

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, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.

1. Set the crankshaft position.
   

   1. Install the crankshaft pulley set bolt, and turn the crankshaft, and set the crankshaft set key at the left horizontal position.

      NOTICE:

      Setting the crankshaft at a wrong angle can cause the piston head and valve head to come into contact with each other when you install the camshaft, causing damage. So always set the crankshaft at the correct angle.

2. Apply new engine oil to the thrust portions and journals of the camshafts.

3. Place the 2 camshafts onto the cylinder head with the cam lobes of No. 2 cylinder facing each correct direction as shown in the illustration.

4. Install the 8 bearing caps in their proper locations.

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

6. Using several steps, install and tighten the 16 bearing cap bolts uniformly in the sequence as shown in the illustration.

   Torque:

   For 10 mm (0.39 in.) head:

   9.0 N*m{92 kgf*cm, 80 in.*lbf}

   For 12 mm (0.47 in.) head:

   24 N*m{245 kgf*cm, 18 ft.*lbf}

1. While pushing in the tensioner, insert a pin of φ1.0 mm (0.039 in.) into the hole to fix it.

2. Install the No. 3 chain tensioner with the bolt.

   Torque:

   19 N*m{194 kgf*cm, 14 ft.*lbf}

1. Align the mark links (yellow) with the timing marks (1-dot mark and 2-dot mark) of the camshaft timing gears as shown in the illustration.

2. Align the timing marks on the camshaft timing gears with the timing marks on the bearing caps, and install the camshaft timing gears with the chain to the LH camshafts.

3. Temporarily install the 2 camshaft timing gear bolts.

   NOTICE:

   Do not push the camshaft timing gear assembly to the camshaft forcibly when installing it.

4. Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts.

   Torque:

   100 N*m{1,020 kgf*cm, 74 ft.*lbf}

5. Remove the pin from the No. 3 tensioner.

1. Install the No. 1 chain vibration damper with the 2 bolts.

   Torque:

   19 N*m{194 kgf*cm, 14 ft.*lbf}

1. Install the No. 2 camshaft bearing to the cylinder head.

   NOTICE:

   Clean the backside of the bearing and the contact surface of the cylinder head and prevent oil from adhering to them.

NOTICE:

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, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.

1. Set the crankshaft position.
   

   1. Using the crankshaft pulley set bolt, turn the crankshaft, and set the crankshaft set key into the left horizontal position.

      NOTICE:

      Having the crankshaft at the wrong angle can cause the piston head and valve head to come into contact with each other when you install the camshaft, causing damage. So always set the crankshaft at the correct angle.

2. Apply new engine oil to the thrust portions and journals of the camshafts.

3. Place the 2 camshafts onto the cylinder head with the cam lobes of No. 1 cylinder facing each direction as shown in the illustration.

4. Install the 8 bearing caps in their proper locations.

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

6. Using several steps, install and tighten the 16 bearing cap bolts uniformly in the sequence as shown in the illustration.

   Torque:

   For 10 mm (0.39 in.) head:

   9.0 N*m{92 kgf*cm, 80 in.*lbf}

   For 12 mm (0.47 in.) head:

   24 N*m{245 kgf*cm, 18 ft.*lbf}

7. Turn the camshafts clockwise until the knock pin comes to 90° position to the cylinder head.

1. While pushing in the tensioner, insert a pin of φ1.0 mm (0.039 in.) into the hole to fix it.

2. Install the No. 2 chain tensioner with the bolt.

   Torque:

   19 N*m{194 kgf*cm, 14 ft.*lbf}

1. Align the mark links (yellow) with the timing marks (1-dot mark) of the camshaft timing gears as shown in the illustration.

2. Align the timing marks on the camshaft timing gears with the timing marks on the bearing caps, and install the camshaft timing gears with the chain to the RH camshafts.

3. Temporarily install the 2 camshaft timing gear bolts.

   NOTICE:

   Do not push the camshaft timing gear assembly to the camshaft forcibly when installing it.

4. Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts.

   Torque:

   100 N*m{1,020 kgf*cm, 74 ft.*lbf}

5. Remove the pin from the No. 2 tensioner.

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

2. Apply soapy water to the O-ring.

3. Install 2 new gaskets and water by-pass joint RR with the 2 bolts and 4 nuts.

   Torque:

   9.0 N*m{92 kgf*cm, 80 in.*lbf}

4. Connect the heater hose.

5. Connect the engine coolant temperature sensor connector.

1. Set a new gasket on each cylinder head.

   NOTICE:

   1. Align the port holes of the gasket and cylinder head.
      
   2. Be careful of the installation direction.
      

2. Set the intake manifold on the cylinder heads.

3. Install and tighten the 10 bolts uniformly in several steps.

   Torque:

   26 N*m{265 kgf*cm, 19 ft.*lbf}

4. Connect the 6 fuel injector connectors.

1. Push the tube connector into the pipe until the tube connector makes a "click" sound.

   NOTICE:

   1. Check if there is any damage or foreign objects on the connected part of the fuel pipe.
      
   2. After connecting, check that the pipe and connector are securely connected by pulling them.
      

2. Install the fuel pipe clamp.

1. Push the tube connector into the pipe until the tube connector makes a "click" sound.

   NOTICE:

   1. Check if there is any damage or foreign objects on the connected part of the fuel pipe.
      
   2. After connecting, check that the pipe and connector are securely connected by pulling them.
      

2. Install the fuel pipe clamp.

1. Set a new gasket to the LH cylinder head with the oval shape facing backward.

   NOTICE:

   Be careful of the installation direction.

2. Install the exhaust manifold with the 6 nuts. Tighten the nuts uniformly in several steps.

   Torque:

   30 N*m{306 kgf*cm, 22 ft.*lbf}

3. Connect the A/F sensor connector.

1. Install the No. 2 manifold stay with the 3 bolts.

   Torque:

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

1. Install 2 new gaskets and the front pipe to the exhaust manifold.

2. Install the exhaust pipe front with the 2 bolts and 2 nuts.

   Torque:

   Nut:

   62 N*m{630 kgf*cm, 46 ft.*lbf}

   Bolt:

   48 N*m{490 kgf*cm, 35 ft.*lbf}

1. Set a new gasket to the RH cylinder head with the oval shape facing forward.

   NOTICE:

   Be careful of the installation direction.

2. Install the exhaust manifold with the 6 nuts. Tighten the nuts uniformly in several steps.

   Torque:

   30 N*m{306 kgf*cm, 22 ft.*lbf}

3. Connect the A/F sensor connector.

1. Install the manifold stay with the 3 bolts.

   Torque:

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

1. Install a new gasket and the front pipe to the exhaust manifold.

2. Install the exhaust pipe front with 2 nuts.

   Torque:

   62 N*m{630 kgf*cm, 46 ft.*lbf}

1. Coat a new O-ring with ATF, and install it to the oil filler tube.

2. Push in the oil filler tube end into the oil pan lower tube.

3. Install the oil filler tube with the bolt.

   Torque:

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

4. Install the ATF level gauge.

1. Install the cool air inlet with air cleaner hose with the 2 bolts.

   Torque:

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

HINT:

(Click here)

1. Fill with fresh engine oil.

   Capacity:

   Drain and refill with oil filter change	5.2 liters (5.5 US qts, 4.6 lmp. qts)
   Drain and refill without oil filter change	4.9 liters (5.2 US qts, 4.3 lmp. qts)
   Dry fill	6.0 liters (6.3 US qts, 5.3lmp. qts)

2. Reinstall the oil filler cap.

1. Fill the radiator with coolant and attach a radiator cap tester.

2. Pump it to 118 kPa (1.2 kgf/cm² 17.1 psi), then check for leakage.

NOTICE:

1. Turn all the electrical systems OFF.
   

1. Operate the inspection when the cooling fan motor is turned OFF.
   

1. Warm up the engine.

2. When using the intelligent tester:
   

   1. Connect the intelligent tester to the DLC3.

   2. Select the following menu items: DIAGNOSIS / ENHANCED OBD ll / DATA LIST / ENGINE SPD.

   3. Inspect the engine idling speed.

      Idling speed:

      650 to 750 rpm (Transmission in neutral position)
      

3. When not using the intelligent tester:
   

   1. Using SST, connect the terminal 8 (TAC) of the DLC3.

      SST

      09843-18030
      

   2. Race the engine speed at 2,500 rpm for approximately 90 seconds.

   3. Inspect the engine idling speed.

      Idling speed:

      650 to 750 rpm (Transmission in neutral position)
      

1. Warm up and stop the engine.

2. Remove the V-bank cover.

3. Remove the air cleaner assembly.

4. Remove the intake air surge tank (Click here).

5. Remove the 6 ignition coils.

6. Remove the 6 spark plugs.

7. Disconnect the 6 injector connectors.

8. Inspect the cylinder compression pressure.
   

   1. Insert a compression gage into the spark plug hole (Procedure "A").

      SST

      09992-00500
      

   2. Fully open the throttle (Procedure "B").

   3. While cranking the engine, measure the compression pressure (Procedure "C").

      Compression pressure:

      1,300 kPa (13.3 kgf/cm², 189 psi)
      

      Minimum pressure:

      1,000 kPa (10.2 kgf/cm², 145 psi)
      

      Difference between each cylinder:

      100 kPa (1.0 kgf/cm², 15 psi)
      

      NOTICE:

      1. Use a fully-charged battery so the engine speed can be increased to 250 rpm or more.
         
      2. Inspect the other cylinders in the same way.
         
      3. Measure the compression in as short a time as possible.
         

   4. Repeat procedures "A" through "C" for each cylinder.

   5. If the cylinder compression is low, pour a small amount of engine oil into the cylinder through the spark plug hole and repeat procedures "A" through "C" for cylinders with low compression.

      1. If adding oil increases the compression, the piston rings and/or cylinder bore may be worn or damaged.
         
      2. If pressure stays low, a valve may be stuck or seated improperly, or there may be leakage from the gasket.
         

9. Connect the 6 injector connectors.

10. Install the 6 spark plugs.

11. Install the 6 ignition coils.

12. Install the intake air surge tank (Click here).

13. Install the air cleaner assembly.

14. Install the V-bank cover.

HINT:

This check is to determine whether or not the idle CO/HC complies with regulations.

1. Start the engine.

2. Run the engine at 2,500 rpm for approximately 180 seconds.

3. Insert the CO/HC meter testing probe at least 40 cm (1.3 ft) into the tailpipe during idling.

4. Immediately check the CO/HC concentration during idling and/or at 2,500 rpm.

   HINT:

   1. Complete the measurement within 3 minutes.
      
   2. When carrying out the 2 modes (idling and 2,500 rpm) test, the measurement orders are prescribed by the applicable local regulations.
      

5. If the CO/HC concentration does not comply with regulations, troubleshoot in the order given below.
   

   1. Check the A/F sensor and heated oxygen sensor operation.

   2. See the table below for possible causes, then inspect and correct the applicable causes if necessary.
      

      CO	HC	Symptom	Causes
      Normal	High	Rough idling	Faulty ignition: Incorrect timing Fouled, shorted or improperly gapped plugs Incorrect valve clearance Leaky intake and exhaust valves Leaky cylinders
      Low	High	Rough idling (Fluctuating HC reading)	Vacuum leaks: PCV hoses Intake manifold Throttle body Lean mixture causing misfire
      High	High	Rough idling (Black smoke from exhaust)	Restricted air filter Faulty EFI systems: Faulty pressure regulator Faulty engine coolant temperature sensor Faulty mass air flow meter Faulty ECM Faulty injectors Faulty throttle position sensor