• Thoroughly clean all parts to be assembled.
• Before installing the parts, apply new engine oil to all sliding and rotating surfaces.
• Replace all gaskets and oil seals with new ones.
1. INSTALL VALVES
(a) Insert the valves in the cylinder head valve guide bushing. Make sure the valves are installed in correct order.
(b) Using SST, install new oil seals on the valve guide bushings.
(c) Install spring seats, springs and spring retainers.
(d) Using SST, compress the valve retainers and place two keepers around the valve stem.
(e) Tap the stem lightly to assure proper fit.
2. INSTALL VALVE LIFTERS WITH SHIMS
Check that the valve lifters rotates smoothly by hand.
3. INSTALL CAMSHAFTS AND OIL SEALS
(a) Apply engine oil to the lip of a new oil seal.
(b) Install the oil seal to the camshaft.
(c) Coat all bearing journals with engine oil.
<d) Place the camshafts on the cylinder head as shown in the illustration.
HINT: The exhaust camshaft has a distributor (7M-GE) or cam position sensor (7M-GTE) drive gear.
(e) Apply seal packing to the areas indicated in the illustration.
Seal packing: Part No.08826-00080 or equivalent
HINT: Install the No. 1 bearing cap immediately after applying the seal packing.
(f) Place bearing caps on each journal with the front marks pointing toward the front and in numerical order from the front side.
(g) Temporarily install the bearing cap bolts in the several passes in the sequence shown.
(h) Using SST, tap in the camshaft oil seal. SST 09223-50010
HINT: Be careful not to install the oil seal slantwise.
(i) Uniformity tighten the No.3 and No.7 bearing cap bolts in several passes, in the sequence shown.
(j) Uniformily tighten other bearing cap bolts in several passes, in the sequence shown.
(k) Check the camshaft thrust clearance.
4. INSTALL EGR COOLER
Install a new gasket and EGR cooler with the eight bolts. Torque: 140 kg-cm (10 ft-lb, 14 N-m)
5. INSTALL HEATER UNION
Install a new gasket, union, another gasket and union bolt to the cylinder head. Torque the union bolt.
6. INSTALL NO.2 ENGINE HANGER AND GROUND STRAP Torque: 400 kg-cm (29 ft-lb. 39 N-m)
7. INSTALL INTAKE MANIFOLD
(a) Position a new gasket on the cylinder head.
(b) Install the intake manifold and VSV with the two nuts and seven bolts.
(c) Install the EGR valve with the two nuts.
(d) Torque the bolts and nuts. Torque: 180 kg-cm (13 ft-lb. 18 N-m)
Spacer and Black Ring
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