- Assemble the cylinder head, if applicable. Refer to
Cylinder Head Assemble.
- Install the cylinder head gasket.
- Install the cylinder head with the intake manifold and the exhaust manifold attached.
- Install new cylinder head bolts.
Notice: Refer to Fastener Notice in the Preface section.
- Tighten the cylinder head bolts gradually and in the sequence shown.
Tighten
Tighten the bolts to 25 N·m (18 lb ft). Adjust the bolts to 60 degrees plus 60 degrees plus 60 degrees plus 10 degrees using
J 45059
or
KM-470-B
.
- Connect the heater outlet hose to the coolant pipe.
- Install the rear timing belt cover.
- Install the bolts to the rear timing belt cover.
Tighten
Tighten the bolts to 10 N·m (89 lb in).
- Install the CMP sensor. Install the CMP sensor bolts.
Tighten
Tighten the bolts to 12 N·m (106 lb in).
- Install the timing belt idler pulley. Install the bolt. to the timing belt idler pulley
Tighten
Tighten the bolt to 40 N·m (30 lb ft).
- Install the timing belt automatic tensioner. Install the bolts to the timing belt automatic tensioner.
Tighten
Tighten the bolts to 25 N·m (18 lb ft).
Notice: Use extreme care when installing the camshaft not to nick, scratch, or damage
the camshaft lobes or bearing surfaces.
- Install the intake camshaft gear.
- While holding the intake camshaft firmly in place, install the intake camshaft gear bolt.
Tighten
Tighten the bolt to 67.5 N·m (49 lb ft).
- Install the exhaust camshaft gear.
- While holding the exhaust camshaft firmly in place, install the exhaust camshaft gear bolt.
Tighten
Tighten the bolt to 67.5 N·m (49 lb ft).
- Apply a small amount of gasket sealant to the corners of the front camshaft caps and to the top of the seal between the rear valve cover and the cylinder
head.
- Install the valve cover and the valve cover gasket.
- Install the valve cover bolts.
Tighten
Tighten the bolts to 10 N·m (89 lb in).
Important: Ensure that the exhaust camshaft gear dowel pin is approximately in the 11 o'clock position.
- Align the timing marks on the camshaft gear.
- Align the mark on the crankshaft gear to the notch at the bottom of the rear timing belt cover.
Notice: Do not use belt dressing on the drive belt. Belt dressing
causes the breakdown of the composition of the drive belt. Failure to follow
this recommendation will damage the drive belt.
- Inspect the timing belt. Refer to
Timing Belt Inspection. If the belt is in good working condition, install the timing belt.
- Rotate the coolant pump clockwise until the adjust arm pointer of the timing belt automatic tensioner is aligned to the notch in the timing belt automatic tensioner bracket.
Notice: Refer to Fastener Notice in the Preface section.
- Tighten the coolant pump retaining bolts.
- Rotate the crankshaft 2 full turns clockwise using the crankshaft pulley bolt.
- Loosen the coolant pump retaining bolts.
- Rotate the coolant pump until the adjust arm pointer of the timing belt automatic tensioner is aligned with the pointer on the timing belt automatic tensioner bracket.
- Tighten the coolant pump retaining bolts.
Tighten
Tighten the coolant pump retaining bolts to 10 N·m (89 lb in).
- Install the retaining bolts that secure the engine mount to the engine mount bracket.
Tighten
Tighten the retaining bolts to 60 N·m (44 lb ft).
- Install the lower front timing belt cover.
- Install the bolts to the lower front timing belt cover.
Tighten
Tighten the bolts to 10 N·m (89 lb in).
- Install the crankshaft pulley.
- Install the crankshaft pulley bolt.
Tighten
Tighten the bolt to 95 N·m (70 lb ft) using a torque wrench. Using
J 45059
or
KM-470-B
, tighten the crankshaft pulley bolt to 30 degrees plus 15 degrees.
- Install the upper front timing belt cover.
- Install the bolts to the upper front timing belt cover.
Tighten
Tighten the bolts to 10 N·m (89 lb in).
- Connect the upper radiator hose to the thermostat housing.
- Connect the throttle body coolant hose to the thermostat housing.
- Install the catalytic converter. Refer to
Catalytic Converter Replacement.
- Install the exhaust manifold heat shield. Install the bolts to the exhaust manifold heat shield.
Tighten
Tighten the bolts to 15 N·m (11 lb ft).
- Connect the ECT sensor connector.
- Install the upper bolts to the intake manifold support bracket.
Tighten
Tighten the bolts to 25 N·m (18 lb ft).
- Install the canister purge solenoid valve at the intake manifold support bracket.
- Install the engine under-cover.
- Connect the front HO2S connector.
- Connect the EI system ignition coil connector.
- Connect the EGR valve connector.
Notice: Do not use belt dressing on the drive belt. Belt dressing
causes the breakdown of the composition of the drive belt. Failure to follow
this recommendation will damage the drive belt.
- Install the accessory drive belt.
- Install the alternator bracket retaining nut.
Tighten
Tighten the nut to 25 N·m (18 lb ft).
- Install the alternator nut. Do NOT tighten.
- Connect the fuel line at the fuel rail.
- Connect the fuel injector harness connectors.
- Connect the ignition wires from the spark plugs.
- Connect the CMP sensor connector.
- Connect the crankcase ventilation tube to the valve cover.
- Connect the breather tube to the valve cover.
- Install the engine cover.
- Install the engine cover bolts.
- Connect the VGIS vacuum tank hose.
- Connect the VGIS connector.
- Connect the brake booster vacuum hose.
- Connect the MAP sensor connector.
- Connect the engine coolant inlet/outlet hose to the throttle body.
- Connect the throttle cable to the throttle body and the intake manifold.
- Connect the TP sensor connector.
- Connect the IAC valve connector.
- Connect the A/C pressure transducer connector.
- Install the air filter housing. Install the air filter housing bolts.
Tighten
Tighten the bolts to 8 N·m (71 lb in).
- Connect the air intake tube to the throttle body.
- Connect the IAT sensor connector.
- Connect the breather tube to the valve cover.
- Install the fuel pump fuse.
- Connect the negative battery cable.
- Fill the engine cooling system. Refer to
Cooling System Draining and Filling.