Page 1241 of 2389

F. Inspect camshaft journal oil clearance
(a) Clean the bearing caps and camshaft journals.
(b) Place the camshafts on the cylinder head.
(c) Lay a strip of Plastigage across each of the camshaft jour-
nals.
(d) Install the bearing caps.
(See step 4 on pages EM±68 and 69)
Torque: 190 kg±cm (14 ft±Ib, 19 N±m )
HINT: Do not turn the camshaft.
(e) Remove the bearing caps.
(f) Measure the Plastigage at its widest point.
Standard oil clearance: 0.025 ± 0.062
(0.0010 ± 0.0024 in.)
Maximum oil clearance 0.10 mm (0.0039 in.)
If the oil clearance is greater than maximum, replace the cam-
shaft. If necessary, replace the bearing caps and cylinder
head as a set.
(g) Completely remove the Plastigage.
G. Inspect camshaft thrust clearance
(a) Install the camshafts.
(See step 4 on pages EM±67 and 69)
(b) Using a dial indicator, measure the thrust clearance while
moving the camshaft back and forth.
Standard thrust clearance:
Intake 0.045 ± 0.100 mm
(0.0018 ± 0.0039 in.)
Exhaust 0.030 ± 0.085 mm
(0.0012 ± 0.0033 in.)
Maximum thrust clearance:
Intake 0.12 mm (0.0047 in.)
Exhaust 0.10 mm (0.0039 in.)
If the thrust clearance is greater than maximum, replace the
camshaft. If necessary, replace the bearing caps and cylin-
der head as a set.E. Inspect camshaft gear spring
Using calipers, measure the free distance between the
spring end.
Free distance: 22.5 ± 22.9 mm (0.886 ± 0.902 in.)
If the free distance is not as specified, replace the gear
spring.
± ENGINE MECHANICALCylinder Head (3S±FE)EM±64
Page 1242 of 2389

H. Inspect camshaft gear backlash
(a) Install the camshafts without installing the exhaust cam
sub±gear.
(See step 4 o n page EM±68 to 70)
(b) Using a dial indicator, measure the backlash.
Standard backlash: 0.020 ± 0.200 mm
(0.0008 ± 0.0079 in.)
Maximum backlash 0.30 mm (0.0188 in.)
If the backlash is greater than maximum, replace the cam-
shafts.
15. INSPECT VALVE LIFTERS AND LIFTER BORES
(a) Using a micrometer, measure the lifter diameter.
Lifter diameter: 27.975 ± 27.985 mm
(1.1014 ± 1.1018 in.)
(c) Subtract the lifter diameter measurement from the lifter
bore diameter measurement.
Standard oil clearance: 0.015 ± 0.046 mm
(0.0005 ± 0.0018 in.)
Maximum oil clearance: 0.07 mm (0.0028 in.)
If the oil clearance is greater than maximum, replace the
lifter. If necessary, replace the cylinder head.
16. INSPECT INTAKE AND EXHAUST MANIFOLDS
Using a precision straight edge and feeler gauge, measure
the surface contacting the cylinder head for warpage.
Maximum warpage: 0.30 mm (0.0118 in.)
If warpage is greater than maximum, replace the manifold. (b) Using a caliper gauge, measure the lifter bore diameter
of the cylinder head.
Lifter bore diameter: 28.000 ± 28.021 mm
(1.1024 ± 1.1032 in.)
± ENGINE MECHANICALCylinder Head (3S±FE)EM±65
Page 1243 of 2389
ASSEMBLY OF CYLINDER HEAD
(See page EM±48)
HINT:
wThoroughly clean all parts to be assembled.
wBefore installing the parts, apply new engine oil to all
sliding and rotating surfaces.
wReplace all gaskets and oil seals with new ones.
1. INSTALL VALVES
HINT: The intake valve oil seal is brown and the exhaust
valve oil seal is black.
(a) Install the following parts:
(1) Oil seal
(2) Valve
(3) Spring seat
(4) Valve spring
(5) Spring retainer
2. INSTALL VALVE LIFTERS AND SHIMS
(a) Install the valve lifter and shim.
(b) Check the valve lifter rotates smoothly by hand. (b) Using SST, compress the valve spring and place the
two keepers around the valve stem.
SST 09202±70010
(c) Using a plastic±faced hammer, lightly tap the valve
stem tip to assure proper fit.
± ENGINE MECHANICALCylinder Head (3S±FE)EM±66
Page 1244 of 2389

1. INSTALL CYLINDER HEAD
A. Place cylinder head on cylinder block
(a) Place a new cylinder head gasket in position on the cylinder
block.
NOTICE: Be careful of the installation direction.
(b) Place the cylinder head in position on the cylinder head gas-
ket.
B. Install cylinder head bolts
HINT:
wThe cylinder head bolts are tightened in two progressive
steps (steps (b) and (d)).
wIf 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) First, using SST, install and uniformly tighten the ten cylinder
head bolts in several passes in the sequence shown.
SST 09011±38121
Torque: 500 kg±cm (36 ft±Ib, 49 N±m)
If any one of the cylinder head bolts does not meet the
torque specification, replace the cylinder head bolt.
(d) 2nd, retighten the cylinder head bolts 90° in the numeri-
cal order shown.
(e) Check that the painted mark is now at a 90° angle to
front.
INSTALLATION OF CYLINDER HEAD
(See page EM±48)
(c) Mark the front of the cylinder head bolt head with
paint. .
± ENGINE MECHANICALCylinder Head (3S±FE)EM±67
Page 1245 of 2389

.
(d) Insert a service bolt (A) into the service hole of the camshaft
sub±gear.
(e) Using a screwdriver, align the holes of the camshaft main
gear and sub±gear by turning camshaft sub±gear clock-
wise, and install a service bolt (B).
NOTICE: Be careful not damage the camshaft.
4. INSTALL CAMSHAFTS
HINT: Since the thrust clearance of the camshaft is small,
the camshaft must be held 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
(a) Apply MP grease to the thrust portion of the camshaft.
(b) Place the intake camshaft at 80° BTDC of camshaft angle
on the cylinder head. 2. INSTALL SPARK PLUG TUBES
(a) Clean the cylinder head tube holes of any residual adhesive, oil
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) Install the spark plug tube nut and using a 30 mm socket
wrench, torque the nuts.
Torque: 400 kg±cm (29 ft±lb, 39 N±m)
3. ASSEMBLE EXHAUST CAMSHAFT
(a) Mount the hexagonal wrench head portion of the camshaft
in a vice.
(b) Install the following parts:
(1) Camshaft gear spring
(2) Camshaft sub±gear
(3) Wave washer
(c) Using snap ring pliers, install the snap ring.
± ENGINE MECHANICALCylinder Head (3S±FE)EM±68
Page 1246 of 2389
(e) Apply alight coat of engine oil on the threads and under
the heads of the bearing cap bolts.
(f) Install and uniformly tighten the ten bearing cap bolts in
several passes in the sequence shown.
Torque: 190 kg±cm (14 ft±Ib, 19 N±m)
(c) Apply seal packing to the front bearing cap as shown.
Seal packing: Part No. 08826±00080 or equivalent
(h) Using SST, tap in the oil seal.
SST 09223±46011 (d) Install the bearing caps in their proper locations.
(g) Apply MP grease to a new oil seal lip.
± ENGINE MECHANICALCylinder Head (3S±FE)EM±69
Page 1247 of 2389

(b) Apply MP grease to the thrust portion of the camshaft.
(c) Engage the exhaust camshaft gear gear to the intake
camshaft gear by matching the timing marks on each
gear.
(d) Roll down the exhaust camshaft onto the bearing jour-
nals while engaging gears with each other.
NOTICE: There are also assembly reference marks on
each gear as shown in the illustration. Do not use
these
marks.
(e) Turn the intake camshaft clockwise or counterclock-
wise little by little until the exhaust camshaft sits in the
bearing journals evenly without rocking the camshaft
on the bearing journals.
NOTICE: This is very important to replace the camshaft
in the bearing journals evenly while tightening bearing
caps in the subsequent steps.
(f) Install the bearing caps in their proper location.
(g) Apply alight coat of engine oil on the threads and under
the heads of bearing cap bolts.
(h) Install and uniformly tighten the ten bearing cap bolts
in several passes in the sequence shown.
Torque: 190 kg±cm (14 ft±lb, 19 N±m)
(i) Remove the service bolt (8).
5. INSTALL CYLINDER HEAD COVER
(a) Apply seal packing to the cylinder head as shown in the fig-
ure.
Seal packing: Part No.08826±00080 or equivalent B. Install exhaust camshaft
(a) Set the knock pin of the intake camshaft at 100 BTDC of
camshaft angle.
± ENGINE MECHANICALCylinder Head (3S±FE)EM±70
Page 1248 of 2389

6. INSTALL N0.3 TIMING BELT COVER
Install the timing belt cover with the four bolts.
7. INSTALL NO.1 IDLER PULLEY AND TENSION SPRING
(See step 4 on page EM±29)
8. INSTALL CAMSHAFT TIMING PULLEY
(See steps 9 to 13 on pages EM±30 to 32)
9. INSTALL SPARK PLUGS (See page IG±7)
Torque: 180 kg±cm (13 ft±lb, 18 N±m)
10. INSTALL INJECTOR AND DELIVERY PIPE
(See steps 1 and 5 on pages FI±91 to 92)
11. INSTALL INTAKE MANIFOLD
(a) Install a new gasket and the intake manifold with the six bolts
and two nuts.
Torque: 195 kg±cm (14 ft±lb, 19 N±m)
12. INSTALL AIR TUBE
(a) Install the air tube with the two bolts.
lbf Connect the following air hoses:
(1) Air intake chamber air hose
(2) Throttle body air hose
(3) (w/ PS)
PS pump air hose
13. INSTALL COLD START INJECTOR PIPE
(See steps 2 and 3 on page FI±80)
14. INSTALL THROTTLE BODY
(See steps 2 and 4 on page FI±109) (b) Install the gasket to the head cover.
(c) Install the head cover with the four grommets and nuts.
Torque: 230 kg±cm (17 ft±Ib, 23 N±m)
HINT: Install the grommets so that it's markings are as
shown in the illustration. Then install the grommet to its
original position.
(b) Install the two manifold stay with the four bolts.
Torque:
12 mm bolt head 195 kg±cm (14 ft±I b, 19 N±m)
14 mm bolt head 425 kg±cm (31 ft±lb, 42 N±m)
(c) Connect the vacuum sensing hose.
± ENGINE MECHANICALCylinder Head (3S±FE)EM±71