Part 1

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

Note: Position crankshaft at No.1 TDC.

CAUTION: Be careful of the installation direction.

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





2. Install cylinder head bolts.

NOTE:

^ The cylinder head bolts are tightened in two progressive steps (steps (b) and (d)).
^ If any cylinder head bolt is broken or deformed, replace it.

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

b. Using SST 09011-38121, install and uniformly tighten the ten cylinder head bolts and plate washers in several passes, in the sequence shown.
Torque: 49 Nm (36 ft lb)

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





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





d. Retighten the cylinder head bolts, turn 90°, in the numerical order shown.
e. Check that the painted mark is now at a 90° angle to front.





3. Install spark plug tubes.
a. Clean the cylinder head tube holes of any residual adhesive, oil or foreign particles. Remove any oil with kerosene or gasoline.
b. Screw the threads of the spark plug tube coated with adhesive into the cylinder head.
c. Using the spark plug tube nut and a 30 mm socket wrench, tighten the spark plug tubes.
Torque: 39 Nm (29 ft lb)
4. Install camshafts.

CAUTION: 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, the following steps should be carried out.





A. Install intake camshaft.
1. Apply multipurpose (Mp) grease to the thrust portion of the camshaft.
2. Place the intake camshaft at 80-115° BTDC of camshaft angle on the cylinder head.

NOTE: The above angle allows the No.1 and No.3 cylinder cam lobes of the intake camshaft to push their valve lifters evenly.





3. Apply seal packing to the No.1 bearing cap as shown. Seal packing: Part No.08826-00080 or equivalent





4. Install the bearing caps in their proper locations.





5. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
6. Install and uniformly tighten the ten bearing cap bolts in several passes, in the sequence shown.
Torque: 19 Nm (14 ft lb)





7. Apply Mp grease to a new oil seal lip.





8. Using SST 09223-46011, tap in the oil seal.





B. Install exhaust camshaft.
1. Set the knock pin of the intake camshaft at 10-45° BTDC of camshaft angle.

NOTE: The above angle allows the No.2 and No.4 cylinder cam lobes of the exhaust camshaft to push their valve liters evenly.





2. Apply MP grease to the thrust portion of the camshaft.
3. Engage the exhaust camshaft gear to the intake camshaft gear by matching the timing marks on each gear.
4. Roll down the exhaust camshaft onto the bearing journals while engaging gears with each other.

NOTE: There are also assembly reference marks on each gear as shown in the illustration. Do not use these marks.





5. Turn the intake camshaft clockwise or counterclockwise little by little until the exhaust camshaft sits in the bearing journals evenly without rocking the camshaft on the bearing journals.

NOTE: It is very important to replace the camshaft in the bearing journals evenly while tightening bearing caps in the subsequent steps.

6. Install the bearing caps in their proper locations.





7. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
8. Install and uniformly tighten the ten bearing cap bolts in several passes. in the sequence shown.
Torque: 19 Nm (14 ft lb)





9. Remove the service bolt (B).

5. Check and adjust valve clearance.
Turn the camshaft and position the cam lobe upward, and check and adjust the valve clearance. Valve clearance (Cold):
Intake:
0.19-0.29 mm (0.007-0.011 in.)
Exhaust:
0.28-0.38 mm (0.011-0.015 in.)
If clearance not within specifications adjust valve clearance.





6. Install semi-circular plugs.
a. Remove any old packing (Formed in Place Gasket (FIPG))material.
b. Apply seal packing to the semi-circular plug grooves. Seal packing:
Part No.08826-00080 or equivalent





c. Install the two semi-circular plugs to the cylinder head.





7. Install PCV valve, PCV hose and high-tension cord clamp to cylinder head.
a. Install the high-tension cord clamp with the bolt.
b. Install the grommet, the PCV valve and hose assembly.
c. Install the PCV hose.





8. Install cylinder head cover.
a. Remove any old packing Formed In Place Gasket (FIPG) material.
b. Apply seal packing to the cylinder head as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent





c. Install the gasket to the head cover.
d. Install the head cover with the 4 grommets and nuts. Uniformly tighten the nuts in several passes.
Torque: 23 Nm (17 ft lb)

NOTE: Install the grommets so that their markings are as shown in the illustration.





9. Install oil pressure switch.
a. Apply adhesive to 2 or 3 threads.
Adhesive: Part No. 08833-00080. THREE BOND 1324 or equivalent





b. Install the oil pressure switch.

10. Install engine hangers and generator bracket.
a. Install the generator bracket and RH engine hanger assembly with the 3 bolts.
Torque: 25 Nm (18 ft lb)
b. Install the LH engine hanger with the bolt.
Torque: 25 Nm (18 ft lb)





11. Install the No. 3 timing belt cover with the 4 bolts.
Torque: 7.8 Nm (69 in. lb)





12. Temporarily install No. 1 idler pulley and tension spring.
a. Align the bracket pin hole with the pivot pin.
b. Install the pulley with the bolt. Do not tighten the bolt yet.
c. Install the tension spring.





d. Pry the pulley toward the left as far as it will go and tighten the bolt.
e. Check that the idler pulley moves smoothly.





13. Install camshaft timing pulley.
a. Align the camshaft knock pin with the knock pin groove of the pulley, and slide on the timing pulley.
b. Using SST 09249-63010, 09960-10010 (09962-01000, 09963-01000), install the pulley bolt.
Torque:
54 Nm (40 ft lb)
37 Nm (27 ft lb) for SST

NOTE: Use a torque wrench with a fulcrum length of 340 mm (13.39 in.)





14. Connect timing belt to camshaft timing pulley.





15. Install injectors and delivery pipe.
a. California: Install a new insulator and grommet to each injector.
b. Except California: Install a new grommet to each injector.
c. California: Apply a light coat of gasoline onto 2 new O-rings, and install them to each injector.
d. Except California: Apply a light coat of gasoline onto a new O-ring. and install it to each injector.





e. While turning the injector clockwise and counterclockwise, push it to the delivery pipe. Install the 6 injectors.
f. Position the injector connector upward.





g. Install the following parts to the intake manifold:
(1) 2 spacers
(2) Except California: 4 new insulators





h. Attach the 4 injectors together with the delivery pipe to the cylinder head.
i. Temporarily install the 2 bolts holding the delivery pipe to the cylinder head.





j. Check that the injectors rotate smoothly.

NOTE:If injectors do not rotate smoothly, the probable cause is incorrect installation of O-rings. Replace the O-rings.

k. Position the injector connector upward.





l. Tighten the 2 bolts holding the delivery pipe to the cylinder head.
Torque: 13 Nm (9 ft lb)





16. California only: Connect the air hose for the air assist system to the cylinder head port.





17. Install intake manifold.
a. Insert the intake manifold between the cylinder head and dash panel.
b. Insert the engine wire between the cylinder head and intake manifold.
c. Install a new gasket and the intake manifold with the 6 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.
Torque: 19 Nm (14 ft lb)





18. Connect the fuel inlet hose to the delivery pipe with 2 new gaskets and the union bolt.
Torque: 34 Nm (25 ft lb)

CAUTION: Be careful of the fuel inlet hose installation direction.

19. Connect fuel return hose to return hose.





20. Install engine wire.
a. Install the engine wire protector to the 2 mounting bolts of the No. 2 timing belt cover in the sequence shown.





b. Install the the engine wire protector to the 2 brackets on the front side of the intake manifold.





c. Connect the 4 injector connectors.

NOTE: The No. 1 and No. 2 injector connectors are brown. and the No. 2 and No. 4 injector connectors are gray.





d. Install the the engine wire protector to the LH side of the intake manifold with the bolt.
e. Connect the Vehicle Speed Sensor (VSS) sensor connector.





f. Install the the engine wire protector to the bracket on the starter.