Cylinder Head, Intake Manifold, Exhaust Manifold: Installation

1. Place a new cylinder head gasket in position on the cylinder block.
   NOTE: Be sure to install it correctly.
2. Place the cylinder head in position on the cylinder head gasket.

Fig 1: Placing Cylinder Head On Cylinder Block

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HINT:

• The cylinder head bolts are tightened in 2 progressive steps (steps  c and  f).
• If any of bolts break or deform, replace them.

1. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
2. Install the 14 plate washers to each cylinder head bolt.
3. Using a 10 mm bi-hexagon wrench, uniformly tighten the cylinder head bolts, in several passes, in the sequence shown in Fig 2.
   1. Torque: 35 N.m (350 kgf.cm, 26 ft.lbf) 

   If any of the bolts do not meet the torque specification, replace the bolt.

   Fig 2: Tightening Cylinder Head Bolts In Sequence

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4. Mark the front of the cylinder head bolt head with paint.
5. Retighten the cylinder head bolts 90° in the numerical order shown in Fig 3.
6. Retighten cylinder head bolts by an additional 90° shown in Fig 3.
   Fig 3: Retightening Cylinder Head Bolts An Additional 90°

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7. Check that the painted mark is now turned to the rear.

1. Apply engine oil to the thrust portion of the camshaft.
2. Place the camshaft on the cylinder head with the cam lobe facing up as shown in Fig 4.
   Fig 4: Placing Cam Lobe Facing Up

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3. Place the (Nos. 3, 7 journal) camshaft bearing caps in their proper location.
4. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
5. Temporarily tighten these bearing cap bolts uniformly and alternately, in several passes, until the bearing caps are snug with the cylinder head.
   Fig 5: Tightening Bearing Cap Bolts

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6. Apply MP grease to a new camshaft oil seal lip.
7. Install the 2 oil seals to the camshafts.
   Fig 6: Installing Oil Seals To Camshaft

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8. Clean the installed surfaces of the Nos. 1, 3 camshaft bearing cap and cylinder head with cleaner.
9. Apply seal packing to the bearing caps as shown in Fig 7.
   1. Seal packing: Part No. 08826-00080 or equivalent. 
   Fig 7: Applying Seal Packing To Bearing Caps

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10. Install the other bearing caps in their proper locations.
11. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
12. Install and uniformly tighten the 14 bearing cap bolts on one side, in several passes, in the sequence shown in Fig 8.
    1. Torque: 20 N.m (200 kgf.cm, 15 ft.lbf) 
    Fig 8: Tightening Bearing Cap Bolts In Sequence

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13. Using a 5 mm hexagon wrench, the 2 No. 3 camshaft bearing cap bolts.
    1. Torque: 5.0 N.m (50 kgf.cm, 44 in..lbf) 
14. Using SST, push the 2 oil seals in as far as they can go.
    1. SST 09316-60011 (09316-00011, 09316-00051)
    Fig 9: Pushing In Oil Seals Using SST

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15. Rotate the camshaft with a wrench at the hexagon position, bring the forward straight pin up.
16. Loosen the 12 bearing cap bolts as shown in Fig 10, until they can be turned by hand; retighten in several passes.
    1. Torque: 20 N.m (200 kgf.cm, 15 ft.lbf) 
    Fig 10: Turning Camshaft And Loosening Camshaft Bearing Cap Bolts (1 Of 3)

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17. Turn the camshaft 1/3 of a revolution.
18. Loosen the 8 bearing cap bolts as shown in Fig 11, until they can be turned by hand; retighten in several passes.
    1. Torque: 20 N.m (200 kgf.cm, 15 ft.lbf) 
    Fig 11: Turning Camshaft And Loosening Camshaft Bearing Cap Bolts (2 Of 3)

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19. Turn the camshaft a further 1/3 of a revolution.
20. Loosen the 8 bearing cap bolts as shown in Fig 12, until they can be turned by hand; retighten in several passes.
    1. Torque: 20 N.m (200 kgf.cm, 15 ft.lbf) 

Fig 12: Turning Camshaft And Loosening Camshaft Bearing Cap Bolts (3 Of 3)

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Install the timing belt cover with 4 bolts.

1. Torque: 8.0 N.m (80 kgf.cm, 71 in..lbf) 

1. Install the exhaust camshaft timing pulley.
   1. Align the camshaft knock pin with the groove in the pulley, and slide on the pulley.
   2. Slide the timing pulley on the camshaft, facing the front mark forward.
   3. Hold the hexagon portion of the camshaft with a wrench, and tighten the timing pulley bolt.

      Torque: 81 N.m (810 kgf.cm, 60 ft.lbf) 

   Fig 13: Installing Camshaft Timing Pulleys

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2. Install the VV-i (intake camshaft timing) pulley (See INSTALLATION  ).

1. Remove the any old packing (FIPG) material.
2. Apply seal packing to the cylinder head as shown in the illustration.
   1. Seal packing: Part No. 08826-00080 or equivalent 
   Fig 14: Applying Seal Packing To Cylinder Head

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3. Install the gaskets to the cylinder head covers.
4. Install the cylinder head covers with the 12 bolts.
   1. Torque: 8.5 N.m (85 kgf.cm, 75 in..lbf) 
5. Using a torx socket (E5), install the 4 stud bolts.
   1. Torque: 8.5 N.m (85 kgf.cm, 75 in..lbf) 
6. Install the 4 nuts to the stud bolts.
   1. Torque: 8.5 N.m (85 kgf.cm, 75 in..lbf) 
   Fig 15: Installing Stud Bolt Using Torx Socket

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1. Install a new gasket and the intake manifold and delivery pipe assembly with the 7 bolts and 2 nuts.
   1. Torque: 28 N.m (280 kgf.cm, 21 ft.lbf) 
2. Pass the water bypass hose between the No. 2, No. 3 intake ports of the manifold and delivery pipe.
3. Install the manifold stay with the 2 bolts.
   1. Torque: 40 N.m (400 kgf.cm, 30 ft.lbf) 
4. Install the starter wire to the manifold stay.

Fig 16: Installing Intake Manifold Assembly

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1. Install the engine wire protector with the 3 nuts.
   Fig 17: Installing Engine Wire Protector Nuts

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2. Using a 5 mm hexagon wrench, install the bolt holding the engine wire protector to the No. 2 cylinder head cover.
3. Connect the 6 injector connectors.

   HINT:

   The Nos. 1, 3, 5 injector connectors and dark gray, and the Nos. 2, 4, 6 injector connectors are brown.

4. Connect the camshaft timing oil control valve connector.
5. Connect the camshaft position sensor connector.
6. Connect the ECT sensor connector.
7. Connect the 2 knock sensor connector.
8. Connect the starter connector.
9. Connect the oil pressure switch connector.
10. Connect the oil level sensor connector.
11. Install the clamp bracket to the intake manifold.
    Fig 18: Installing Clamp Bracket To Intake Manifold

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12. Connect the 2 wire clamps to the No. 1 oil pipe and clamp bracket on the intake manifold.
13. Install the 2 ground terminals to the intake manifold. Tighten so that each calking part should face inside.
14. Install the clamp bracket to the water pump.
    Fig 19: Installing Clamp Bracket To Water Pump

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15. Connect the generator connector.
16. Connect the crankshaft position sensor connector.
17. Connect the heated oxygen sensor (bank 1 sensor 1) connector.
18. Secure the engine wire with the clamp.
19. Install the 2 hose clamps to the cylinder head and oil filter bracket.
    Fig 20: Installing Hose Clamps And Oil Filter Bracket

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20. Install the heated oxygen sensor (bank 2 sensor 1) connector and engine wire clamp to the hose clamps.
21. Install the 2 water bypass hoses to the hose clamps on the cylinder head and oil filter bracket.
22. Install the ground strap to the cylinder head.

1. Torque: 8.0 N.m (80 kgf.cm, 71 in..lbf) 

1. Install the vacuum control valve set and No. 2 vacuum pipe with the 3 nuts.
   1. Torque: 21 N.m (210 kgf.cm, 15 ft.lbf) 
   Fig 21: Installing Vacuum Control Valve Set And No. 2 Vacuum Pipe

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2. Install the engine wire clamp to the clamp bracket of the No. 2 vacuum pipe.
3. Connect the VSV connector for the ACIS.

1. Install 2 new gaskets to the cylinder head.
2. Using a 14 mm deep socket wrench, install the exhaust manifold with the 8 nuts. Uniformly tighten the nuts in several passes.
   1. Torque: 40 N.m (410 kgf.cm, 30 ft.lbf) 
   Fig 22: Installing Exhaust Manifold Nuts

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3. Connect the 3 heated oxygen sensor connectors and clamp.
4. Install a new clamp and the case clamp as shown in Fig 23 .
   Fig 23: Installing Clamp And Case Clamp

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1. Temporarily install the pipe support bracket to the transmission with the 2 bolts.
2. Install 2 new gaskets to front end of the front exhaust pipe, and connect the front exhaust pipe to the exhaust manifold with the 3 bolts nuts and retainer.
   1. Torque: 43 N.m (438 kgf.cm, 32 ft.lbf) 
   Fig 24: Connecting Front Exhaust Pipe To Exhaust Manifold

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3. Connect the wire grommet and sensor wire of the heated oxygen sensor (bank 2 sensor 2) to the hole and clamp on the floor.
   Fig 25: Connecting Wire Grommet And Sensor Wire To Hole

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1. Install the vane pump with the 2 bolts.
   1. Torque: 58 N.m (590 kgf.cm, 43 ft.lbf) 
2. Install the pump rear stay with the 2 bolts.
   1. Torque: 39.2 N.m (400 kgf.cm, 29 ft.lbf) 
3. Connect the PS air hose to the No.4 timing belt cover.
4. Connect the PS air hose to the air intake chamber.

Fig 26: Installing PS Pump

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Install the absorber with the 2 nuts.

1. Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) 

Install the engine cover with the 4 nuts.

Check for abnormal noise, shock, slippage, correct shift points and smooth operation.