Installation

CYLINDER HEAD

COMPONENTS:

INSTALLATION
1. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH

a. Place a new gasket on the cylinder head.

NOTICE: Be careful of the installation direction.

b. Install the exhaust manifold to the cylinder head with 8 new nuts in the order shown in the illustration.
Torque: 44 Nm (449 kgf-cm, 32 ft. lbs.)

2. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
a. Install the heat insulator with the 4 bolts in the order shown in the illustration.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
3. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH

a. Place a new gasket on the cylinder head.

NOTICE: Be careful of the installation direction.

b. Install the exhaust manifold with 8 new nuts in the order shown in the illustration.
Torque: 44 Nm (449 kgf-cm, 32 ft. lbs.)

4. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
a. Install the heat insulator with the 4 bolts in the order shown in the illustration.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)

5. INSTALL CYLINDER HEAD GASKET LH
a. Place a new cylinder head gasket in position on the cylinder block.

HINT: The rear side of the cylinder head gasket has marks so that the bank 1 and bank 2 can be distinguished. An "L" mark is on the bank 1 gasket.

NOTICE: Be careful of the installation direction.

6. INSTALL CYLINDER HEAD LH

a. 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/compression.
b. Install the cylinder head together with the exhaust manifold to the cylinder block.
c. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
d. Put the washers on the bolts, and insert the bolts with washers into the cylinder head.

NOTICE: Be careful not to drop washers into the cylinder head.

e. Install and uniformly tighten the 10 cylinder head bolts and plate washers in the sequence shown in the illustration.
Torque: 40 Nm (408 kgf-cm, 30 ft. lbs.)

7. INSTALL CYLINDER HEAD GASKET RH
a. Place a new cylinder head gasket in position on the cylinder block.

HINT: The rear side of the cylinder head gasket has marks so that the bank 1 and bank 2 can be distinguished. An "R" mark is on the bank 2 gasket.

NOTICE: Be careful of the installation direction.

8. INSTALL CYLINDER HEAD RH

Left Bank:

Right Bank:

e. Install and uniformly tighten the 10 cylinder head bolts, and plate washers in the sequence shown in the illustration.
Torque: 40 Nm (408 kgf-cm, 30 ft. lbs.)

f. Mark the front of the cylinder head bolt's head with paint.
g. Retighten the cylinder head bolts by 90° in the numerical order shown above.
h. Retighten the cylinder head bolts by an additional 90°.
i. Check that the painted mark is now at a 180° angle to the front.
9. INSTALL CAMSHAFT (for Bank 1)

NOTICE: Since 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 receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, these steps should be carried out.

a. Apply engine oil to the cam and gear of the camshaft and also the journal of the cylinder head.

b. Align the timing marks (2 dot marks each) of the camshaft drive and driven main gears, and place the No. 3 and No. 4 camshafts.

c. Apply seal packing to the camshaft housing plug.
^ Remove the old packing (FIPG) material.
^ Apply seal packing to the housing plug as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

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

NOTICE: Be careful of the installation direction.

f. Apply seal packing to the front bearing cap.
^ Remove any old packing (FIPG) material.
^ Apply seal packing to the bearing cap as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
Standard seal diameter: 1.5 to 2.0 mm (0.059 to 0.079 inch)

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

g. Install the front bearing cap.

HINT: Installing the front bearing cap will determine the thrust portion of the camshaft.

h. Install the other bearing caps in the sequence shown, with the arrow mark facing forward.

i. Push in the camshaft oil seal.

j. Install 4 new seal washers to the bearing cap bolts (1 to 4).
k. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts (5 to 22).

NOTICE: Do not apply engine oil under the heads of the bearing cap bolts (1 to 4).

l. Install the oil feed pipe and the 22 bearing cap bolts.
m. Uniformly tighten the 22 bearing cap bolts in several passes in the sequence shown in the illustration.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.) for bolts 21 and 22
16 Nm (163 kgf-cm, 142 inch lbs.) for other bolts
n. Remove the service bolt.

10. INSTALL REAR TIMING BELT PLATE LH
a. Install the rear timing belt plate with the bolt.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
11. INSTALL REAR NO. 2 TIMING BELT PLATE LH
a. Install the rear timing belt plate with the 2 bolts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
12. INSTALL CAMSHAFT TIMING PULLEY LH
a. Align the camshaft timing tube knock pin with the knock pin groove of the timing pulley.
b. Temporarily install the 4 bolts of the camshaft timing pulley.
c. Hold the camshaft timing pulley with SST, and tighten the pulley bolt.
SST 09960-10010 (09962-01000, 09963-01000)
Torque: 8.1 Nm (83 kgf-cm, 72 inch lbs.)

13. INSTALL CAMSHAFT (for Bank 2)

NOTICE: Since 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 receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, these steps should be carried out.

a. Apply engine oil to the cam and gear of the camshaft and also the journal of the cylinder head.
b. Align the timing marks (1 dot mark each) of the camshaft drive and driven main gears, and place the No. 1 and No. 2 camshafts.
c. Set the timing mark (1 dot mark each) of the camshaft drive and driven main gears at an angle of approximately 10°.

d. Apply seal packing to the camshaft housing plug.
^ Remove the old packing (FIPG) material.
^ Apply seal packing to the housing plug as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

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

NOTICE: Be careful of the installation direction.

g. Apply seal packing to the front bearing cap.
^ Remove any old packing (FIPG) material.
^ Apply seal packing to the bearing cap as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
Standard seal diameter: 1.5 to 2.0 mm (0.059 to 0.079 inch)

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

h. Install the front bearing cap.

HINT: Installing the front bearing cap will determine the thrust portion of the camshaft.

i. Install the other bearing caps in the sequence shown, with the arrow mark facing forward.

j. Push in the camshaft oil seal.

k. Install 4 new seal washers to the bearing cap bolts (1 to 4).
l. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts (5 to 22).

NOTICE: Do not apply engine oil under the heads of the bearing cap bolts (1 to 4).

m. Install the oil feed pipe and the 22 bearing cap bolts.
n. Uniformly tighten the 22 bearing cap bolts in several passes in the sequence shown in the illustration.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.) for bolts 21 and 22
16 Nm (163 kgf-cm, 142 inch lbs.) for other bolts.
o. Remove the service bolt.

14. INSTALL REAR TIMING BELT PLATE RH
a. Install the rear timing belt plate with the bolt.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
15. INSTALL REAR NO. 2 TIMING BELT PLATE RH
a. Install the rear timing belt plate with the 2 bolts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)

16. INSTALL CAMSHAFT TIMING PULLEY RH
a. Align the camshaft timing tube knock pin with the knock pin groove of the timing pulley.
b. Temporarily install the 4 bolts of the camshaft timing pulley.
c. Hold the camshaft timing pulley with SST, and tighten the pulley bolt.
SST 09960-10010 (09962-01000, 09963-01000)
Torque: 8.1 Nm (83 kgf-cm, 72 inch lbs.)
17. INSTALL TIMING BELT
a. Install the timing belt.
18. ADJUST VALVE CLEARANCE
a. Adjust valve the clearance.
19. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH

a. Remove any old packing (FIPG) material.
b. Apply seal packing to the cylinder heads as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

NOTICE:
^ Remove any oil from the contact surface.
^ Install the oil pan within 5 minutes after applying seal packing.
^ Do not start the engine within 2 hours after applying seal packing.

c. Install the gasket to the cylinder head cover.
d. Install the 9 seal washers to the bolts.

e. Install the cylinder head cover with the 9 bolts. Uniformly tighten the bolts in several passes.
Torque: 6.0 Nm (61 kgf-cm, 53 inch lbs.)

f. Install a new gasket and the oil filler cap housing with the 2 nuts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
20. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH

e. Install the cylinder head cover with the 9 bolts. Uniformly tighten the bolts in several passes.
Torque: 6.0 Nm (61 kgf-cm, 53 inch lbs.)
21. INSTALL SPARK PLUG
Torque: 17.5 Nm (178 kgf-cm, 13 ft. lbs.)
22. INSTALL IGNITION COIL
a. Install the 8 ignition coils with the 8 bolts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)

23. INSTALL NO. 1 ENGINE HANGER
a. Install the engine hanger with the 2 bolts.
Torque: 37 Nm (377 kgf-cm, 27 ft. lbs.)

24. INSTALL NO. 2 ENGINE HANGER
a. Install the engine hanger with the 2 bolts.
Torque: 37 Nm (377 kgf-cm, 27 ft. lbs.)
25. INSTALL OIL DIPSTICK GUIDE WITH DIPSTICK
a. Install a new O-ring to the dipstick guide.
b. Install the dipstick guide with the bolt.
Torque 15 Nm (153 kgf-cm, 11 ft. lbs.)

26. INSTALL REAR WATER BY-PASS JOINT
a. Install 2 new gaskets and the water by-pass joint with the 4 nuts. Alternately tighten the nuts.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)
27. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY
a. Install a new O-ring to the water by-pass pipe.
b. Apply soapy water to the O-ring.
c. Push in the water by-pass pipe end into the pipe hole of the water pump.
d. Install the water by-pass with the bolt.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)

28. INSTALL FRONT WATER BY-PASS JOINT
a. Install 2 new gaskets and the water by-pass joint with the 4 nuts. Alternately tighten the nuts.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)
b. Connect the ECT connector.

29. INSTALL WATER INLET HOUSING
a. Install a new O-ring to the water inlet housing.
b. Apply soapy water to the O-ring.
c. Apply seal packing to the sealing groove of the inlet housing as shown in the illustration.
Seal packing: Part No. 08826-00100 or equivalent
Standard seal diameter: 2 to 3 mm (0.08 to 0.12 inch lbs.)
30. INSTALL STARTER ASSEMBLY
31. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Bank 1)
32. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Bank 2)
33. INSTALL KNOCK SENSOR
34. INSTALL VVT SENSOR (for Bank 1)
35. INSTALL VVT SENSOR (for Bank 2)
36. INSTALL CAMSHAFT POSITION SENSOR
37. INSTALL AIR PUMP ASSEMBLY
38. INSTALL AIR SWITCHING VALVE ASSEMBLY
39. INSTALL INTAKE MANIFOLD ASSEMBLY
40. INSTALL FRONT EXHAUST PIPE LH
41. INSTALL FRONT EXHAUST PIPE RH
42. INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY
43. INSTALL NO. 1 FUEL PIPE SUB- ASSEMBLY
44. ADD ENGINE COOLANT
45. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
46. PERFORM INITIALIZATION
a. Perform initialization.

NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.