Page 2377 of 3051

SEM084D
3. Check lash adjuster guide hole diameter.
Inner diameter:
17.000 - 17.020 mm (0.6693 - 0.6701 in)
Standard clearance between lash adjuster and adjuster
guide hole:
0.007 - 0.040 mm (0.0003 - 0.0016 in)
SEM063G
ROCKER ARM, SHIM AND ROCKER ARM GUIDENLEM0133S18Check contact and sliding surfaces of rocker arms, shims and
rocker arm guides for wear or score.
AssemblyNLEM0135CAUTION:
+When installing rocker arms, camshaft and oil seal, lubri-
cate contacting surfaces with new engine oil.
+When tightening cylinder head bolts, camshaft sprocket
bolts and camshaft bracket bolts, lubricate bolt threads
and seat surfaces with new engine oil.
AEM116
+If a hydraulic lash adjuster is kept on its side, there is a
risk of air entering it. When hydraulic lash adjusters are
removed, stand them straight up or soak them in new
engine oil.
+Do not disassemble hydraulic lash adjusters.
+Attach tags to lash adjusters so as not to mix them up.
SEM595D
1. Install valve component parts.
+Install valves, noting their identification marks as indi-
cated in the table below.
Identification mark
Intake valve E71
Exhaust valve 6Y2
CYLINDER HEADSR
Inspection (Cont'd)
EM-120
Page 2378 of 3051

SEM085D
+Always use new valve oil seal.
Refer to EM-105.
+Before installing valve oil seal, install valve spring seat.
+Install valve spring (uneven pitch type) with its narrow
pitched side (paint mark) toward cylinder head side.
+After installing valve components, use plastic hammer to
lightly tap valve stem tip to assure a proper fit.
SEM093D
2. Check hydraulic lash adjusters.
a. Push on the rocker arm above the hydraulic lash adjuster. If it
moves 1 mm (0.04 in) or more, there is air in the high pressure
chamber of hydraulic lash adjuster.
Noise will be emitted from hydraulic lash adjuster if engine is
started without bleeding air.
AEM117
b. Remove hydraulic lash adjuster and dip in a container filled
with new engine oil. While pushing plunger as shown in figure,
lightly push check ball using a thin rod. Air is completely bled
when plunger no longer moves.
Air cannot be bled from this type of lash adjuster by running
engine.
SEM202D
3. Install rocker arms, shims, rocker arm guides and hydraulic
lash adjusters.
CAUTION:
Install all parts in their original positions.
SEM364D
4. Select a suitable shim when replacing any of the following
parts with a new one: Cylinder head, shim, rocker arm guide
and valve seat. Proceed as follows to select the shim of cor-
rect thickness.
a. Install valve component parts to cylinder head (Except shim).
+Always replace rocker arm guide with a new one.
CYLINDER HEADSR
Assembly (Cont'd)
EM-121
Page 2379 of 3051
SEM365DA
b. Remove hydraulic lash adjuster.
c. Install Tool* into hydraulic lash adjuster fixing hole.
* Tool (KV10115700) is screwed into magnetic stand rod used
with dial gauge.
d.
SEM899D
Make sure that the following parts are installed to the cylinder
head: Valve, valve spring, collet, retainer and rocker arm guide
(except shim). Measure difference (T
1) between sliding surface
of rocker arm guide and valve stem end on shim side.
When measuring, lightly pull dial indicator rod toward you
to eliminate play in Tool (KV10115700).
SEM096D
e. Select correct shim.
Shim thickness (T):
T
1±0.025 mm (0.0010 in)
+Shims are available in different thicknesses from 2.800 mm
(0.1102 in) to 3.200 mm (0.1260 in) in increments of 0.025 mm
(0.0010 in).
SEM064G
5. Install intake manifold with intake manifold collector as shown.
CYLINDER HEADSR
Assembly (Cont'd)
EM-122
Page 2380 of 3051
SEM059GA
6. Install exhaust manifold.
+Tighten exhaust manifold bolts in numerical order.
Exhaust manifold:
: 49 - 63 N´m (5.0 - 6.5 kg-m, 37 - 47 ft-lb)
SEM060G
7. Install EGR volume control valve assembly.
SEM058G
8. Install EGR tube.
9. Install exhaust manifold cover.
BEM005
10. Install water outlet.
a. Remove old liquid gasket from mating surface of water outlet.
+Also remove old liquid gasket from mating surface of cyl-
inder head.
b. Apply a continuous bead of liquid gasket to mating surface of
water outlet.
+Use Genuine RTV silicone sealant part No. 999MP-A7007
or equivalent.
AEM250
InstallationNLEM01361. Before installing cylinder head gasket, apply liquid gasket as
shown in the illustration.
CYLINDER HEADSR
Assembly (Cont'd)
EM-123
Page 2381 of 3051

SEM390G
SEM877A
2. Install cylinder head completely with intake and exhaust mani-
folds.
+Apply engine oil to threads and seating surfaces of cylin-
der head bolts before installing them.
+Be sure to install washers between bolts and cylinder
head.
Cylinder head bolts are tightened by plastic zone tightening
method. Whenever the size difference between d1 and d2
exceeds the limit, replace them with new ones.
Limit (d1 - d2):
0.15 mm (0.0059 in)
+If reduction of outer diameter appears in a position other than
d2, use it as d2 point.
SEM986C
3. Tighten cylinder head bolts using the following procedure.
a.Tighten all bolts to 39 N´m (4.0 kg-m, 29 ft-lb).
b.Tighten all bolts to 78 N´m (8.0 kg-m, 58 ft-lb).
c.Loosen all bolts completely.
d.Tighten all bolts to 39 N´m (4.0 kg-m, 29 ft-lb).
SEM043G
SEM044G
e.Method A:
Turn all bolts 90 to 95 degrees clockwise with Tool or
suitable angle wrench.
Method B:
If an angle wrench is not available, mark all cylinder head
bolts on the side facing engine front. Then, turn each cyl-
inder head bolt 90 to 95 degrees clockwise.
f.Turn all bolts another 90 to 95 degrees clockwise.
g.Ensure that paint mark on each bolt faces the rear of the
engine. (Method B only)
Do not turn any bolt 180 to 190 degrees clockwise all at once.
CYLINDER HEADSR
Installation (Cont'd)
EM-124
Page 2382 of 3051
AEM113
Tightening torque N´m (kg-m, ft-lb)
a. 39 (4.0, 29)
b. 78 (8.0, 58)
c. 0 (0, 0)
d. 39 (4.0, 29)
e. 90 - 95 degrees (90 degrees preferred)
f. 90 - 95 degrees (90 degrees preferred)
SEM037G
4. Install cylinder head outside bolts.
5. Install the following water hoses:
+Water hose for cylinder block.
+Water hoses for heater.
SEM036G
6. Install starter motor.
BEM004
7. Remove old liquid gasket from mating surface of LH camshaft
end bracket.
+Also remove old liquid gasket from mating surface of cyl-
inder head.
8. Apply liquid gasket to mating surface of LH camshaft end
bracket as shown in illustration.
+Use Genuine RTV silicone sealant part No. 999MP-A7007
or equivalent.
SEM045G
9. Install camshafts, camshaft brackets.
+Position camshaft.
+LH camshaft key at about 12 o'clock.
+RH camshaft key at about 10 o'clock.
Apply new engine oil to bearing and cam surfaces of cam-
shafts before installing them.
CYLINDER HEADSR
Installation (Cont'd)
EM-125
Page 2383 of 3051

SEM098DA
+Position camshaft brackets as shown in the illustration.
Apply new engine oil to threads and seating surfaces of
camshaft bracket bolts before installing them.
SEM046G
+Arrange bolts (Size and length).
A: M6 x 53.8 mm (2.12 in)
B: M6 x 37 mm (1.46 in)
C: M8 x 35 mm (1.38 in)
SEM047G
SEM046G
+Tightening procedure
STEP 1:
RH camshaft
Tighten bolts9-10inthat order then tighten bolts
1-8innumerical order.
: 2 N´m (0.2 kg-m, 17 in-lb)
LH camshaft
Tighten bolts 11 - 12 in that order then tighten
bolts1-10innumerical order.
: 2 N´m (0.2 kg-m, 17 in-lb)
STEP 2:
Tighten bolts in numerical order.
: 6 N´m (0.6 kg-m, 52 in-lb)
STEP 3:
Tighten bolts in numerical order.
Bolt type A B
: 9.8 - 11.8 N´m (1.0 - 1.2 kg-m, 7.2 - 8.7 ft-lb)
Bolt type C
: 18 - 25 N´m (1.8 - 2.6 kg-m, 13 - 19 ft-lb)
SEM048G
10. Install camshaft sprockets and timing chain on them.
Line up mating marks on timing chain with mating marks
on camshaft sprockets.
CYLINDER HEADSR
Installation (Cont'd)
EM-126
Page 2384 of 3051
SEM049G
+Lock camshafts as shown in figure and tighten to specified
torque.
: 137 - 157 N´m (14.0 - 16.0 kg-m, 101 - 116 ft-lb)
Apply new engine oil to threads and seating surfaces of cam-
shaft sprocket bolts before installing them.
SEM050G
11. Install distributor.
+Make sure that position of camshaft is as shown in figure.
SEM033G
+Make sure that No. 1 piston is set at TDC and that distribu-
tor rotor is set at No. 1 cylinder spark position.
SEM990C
SEM991C
12. Install chain tensioner.
Make sure the camshaft sprockets are tightened completely.
Press cam stopper down and ªpress-inº sleeve until hook can
be engaged on pin. When tensioner is bolted in position the
hook will release automatically. Make sure arrow ªAº points
toward engine front.
CYLINDER HEADSR
Installation (Cont'd)
EM-127