LS400 1990-1997

Cylinder Head

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Removal & Installation



Specific to:

Lexus LS400 1993-1994



Click image to see an enlarged view

Fig. Cylinder head removal component view - LS400

  1. Disconnect the negative battery cable. Wait at least 90 seconds before proceeding with any other work.
  2.  
  3. Drain the engine coolant.
  4.  
  5. Disconnect the timing belt from the camshaft timing pulleys.
  6.  
  7. Remove the camshaft timing pulleys. Do not drop any parts into the timing belt cover. Protect the belt from grease, fluids, etc.
  8.  
  9. Remove the fan bracket.
  10.  
  11. Disconnect the air hose from the air intake chamber. Remove the power steering pump pulley. Remove the power steering pump from the engine.
  12.  
  13. Disconnect the front exhaust pipe from the front catalytic converters.
  14.  
  15. Remove the front catalytic converters.
  16.  
  17. Remove the throttle body cover.
  18.  
  19. Disconnect the accelerator cable, the automatic transmission throttle cable and the cruise control actuator cable.
  20.  
  21. Remove the right ignition coil.
  22.  
  23. Remove the inlet housing from the water pump. Disconnect the coolant bypass hose from the IAC valve. Remove the coolant inlet and housing assembly; remove the O-ring from the water inlet housing.
  24.  
  25. Remove the timing belt rear plates.
  26.  
  27. Disconnect the hoses from the throttle body and the fuel pressure regulator. Disconnect the vacuum hose from the air intake chamber (from fuel pressure VSV) and disconnect the charcoal canister hose line from the vacuum pipe. Disconnect the vacuum hoses from the VSVs for fuel pressure regulator, EVAP and the charcoal canister. Remove the 2 bolts and remove the vacuum pipe and hose assembly.
  28.  
  29. To remove the EGR, disconnect the coolant bypass pipe from the hose (from the IAC valve). Also disconnect the coolant pipe from the hose at the rear bypass joint. Remove the EGR valve and gasket.
  30.  
  31. Disconnect the EGR temperature sensor connector. Disconnect the PCV hose from the cylinder head. Remove the EGR valve adapter.
  32.  
  33. Remove the IAC valve.
  34.  
  35. Disconnect the wires and hoses; remove the throttle body assembly.
  36.  
  37. Disconnect the brake booster vacuum hose at the union on the air intake chamber. Disconnect the vacuum hoses from the air intake chamber.
  38.  
  39. Remove the accelerator bracket. Remove the union bolt and the union. Disconnect the VSV connectors for the fuel pressure, EVAP and AIR. Disconnect the EGR pipe from the air intake chamber.
  40.  
  41. Remove the VSVs. Disconnect the DIAGNOSIS data link connector from the air intake chamber. Remove the air intake chamber.
  42.  
  43. Disconnect the heater hoses from the rear bypass joint and pipes.
  44.  
  45. Disconnect the fuel inlet pipe from the delivery pipe. Remove the pulsation damper.
  46.  
  47. Disconnect the wiring harness from the clips and brackets on the right cylinder head. Remove the wire brackets from the cylinder head. Disconnect the engine wiring harness from the intake manifold.
  48.  
  49. Disconnect the engine wiring harness from the delivery pipes. Disconnect the injector wiring connectors.
  50.  
  51. Disconnect the wire harness from the rear water bypass joint. for California vehicles, disconnect the harness connector.
  52.  
  53. Remove the fuel return pipe. Remove the fuel delivery pipes and the remove the injectors. Take care not to drop or damage the injectors.
  54.  
  55. Remove the intake manifold.
  56.  
  57. Remove the front coolant bypass joint, then remove the rear bypass joint.
  58.  
  59. For California vehicles, remove the water bypass pipe.
  60.  
  61. Remove the oil dipsticks and tubes for both the engine and transmission.
  62.  
  63. For California vehicles, remove the secondary air injection (AIR) manifolds.
  64.  
  65. Remove the rear water bypass joint.
  66.  
  67. For non-Calif. vehicles, remove the water bypass pipe.
  68.  
  69. Remove the EGR pipe.
  70.  
  71. Disconnect the engine wiring harness and the ground straps from the cylinder heads.
  72.  
  73. Remove the engine hangers (hoist hooks).
  74.  
  75. Remove the cylinder head covers (valve covers). If necessary, remove the semi-circular plugs.
  76.  
  77. Remove the camshafts.
    NOTE
    Since the thrust clearance of the camshaft is small, the camshaft must be held level while it is being removed. If the camshaft is not kept level, the portion of the head receiving the thrust may crack or be damaged, causing the camshaft to seize or break during operation.

  78.  
  79. Uniformly loosen the 10 bolts on 1 cylinder head in the reverse order of tightening. Make several repetitive passes in sequence, loosening each bolt slightly each time. Repeat the loosening procedure for the other head.
    NOTE
    The head(s) may crack or warp if correct bolt loosening procedure is not followed.



    Click image to see an enlarged view

    Fig. Cylinder head bolt tightening sequence

  80.  
  81. Remove the 20 cylinder head bolts and plate washers. Lift the heads, with the exhaust manifold attached, from the dowels on the block. Place the heads on blocks of wood on the workbench.
    NOTE
    If necessary to pry the head loose, take great care not to damage the contact surfaces of the head or block.

  82.  
  83. For each exhaust manifold, remove the main heated oxygen sensor, then remove the manifold and gasket. To install:
  84.  
  85. Install the right exhaust manifold. The new gasket must be installed with the yellow marks facing the manifold side. Tighten the bolts to 33 ft. lbs. (44 Nm). Connect the right oxygen sensor connector.
  86.  
  87. Install the left exhaust manifold. The new gasket must be installed with the yellow marks facing the manifold side. Tighten the bolts to 33 ft. lbs. (44 Nm). Connect the left oxygen sensor connector.
  88.  
  89. Place the two new cylinder head gaskets in position on the engine block. Each gasket has a painted mark denoting the rear of the gasket. The gasket for the right bank has a white mark and the gasket for the left bank has a yellow mark. Double check the gasket position and placement.

    Click image to see an enlarged view

    Fig. The head gaskets are marked for correct placement

  90.  
  91. Place the two cylinder heads in position on the block.
  92.  
  93. Apply a light coat of engine oil to the threads and under the head of each bolt. Temporarily install the 20 plate washers and bolts.
  94.  
  95. Uniformly tighten the 10 bolts on 1 cylinder head in the correct tightening sequence. Make several repetitive passes in this order, tightening each bolt slightly each time. Final torque for each bolt is 29 ft. lbs. (39 Nm). Repeat the tightening procedure for the other head.
  96.  
  97. Carefully mark the front of each bolt with a small dot of paint. Following the tightening sequence used earlier, retighten each bolt by turning it exactly 90 degrees. Check that each paint mark is now at a 90 degree angle to the front of the engine.

    Click image to see an enlarged view

    Fig. Apply a dot of paint at the front of each bolt



    Click image to see an enlarged view

    Fig. The paint mark must be 90 degrees from the starting point - LS400

  98.  
  99. Connect the oxygen sensor connectors.
  100.  
  101. Install new circular plugs on the heads with the cup side facing forward. Remove any old packing material and apply new sealant to the correct bearing caps.
    1. On the right cylinder head, install the bearing cap marked I1 in position with the arrow facing rearward.
    2.  
    3. On the left cylinder head, install the bearing cap marked I6 in place with the arrow facing forward.
    4.  
    5. Install a new seal washer to the bearing cap bolt. Apply a light coat of engine oil to the threads of the silver-colored bearing cap bolts.
    6.  
    7. Install the 4 bolts for the bearing caps. Tighten them to 12 ft. lbs. (16 Nm).
    8.  

  102.  
  103. Assemble and install the camshafts onto the heads. Check and adjust the valve clearance.
    NOTE
    Since 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 head receiving the thrust may crack or be damaged, causing the camshaft to seize or break during operation.

  104.  
  105. Install the semi-circular plugs. Clean the plug of old sealant and apply new sealant to the plug groove.
  106.  
  107. Clean the cylinder head covers. Apply new sealant in the correct locations and install the gaskets. Install the cylinder head covers and bolts. Tighten the bolts to 52 inch lbs. (6 Nm).
  108.  
  109. Install the engine hangers. Tighten the hanger bolts to 27 ft. lbs. (37 Nm).
  110.  
  111. Install the engine harness to the cylinder heads; install the protectors and connect the ground strap.
  112.  
  113. Install the EGR pipe with new gaskets. Use the 25mm (0.98 in) bolts and tighten them to 13 ft. lbs. (18 Nm).
  114.  
  115. On non-California vehicles, install the water bypass pipe.
  116.  
  117. Install the rear water bypass joint.
  118.  
  119. For California vehicles, install the secondary air injection manifold on each side. Tighten the 4 nuts to 25 ft. lbs. (34 Nm). Tighten the bolt to 13 ft. lbs. (18 Nm). Connect a new three-way air hose to the left AIR manifold.
  120.  
  121. Install the oil dipsticks and tubes.
  122.  
  123. Install the front water bypass joint and the water bypass pipe.. Use new gaskets and connect the hoses. Tighten the bolts to 13 ft. lbs. (18 Nm). On California vehicles, install the AIR inlet pipe, then connect the ECT sensor and gauge sender connectors.
  124.  
  125. Before installing the intake manifold, place two new gaskets on the cylinder heads with the white painted mark facing upward. Double check the positioning and alignment of the gasket. Place the manifold on the heads with the arrow facing forward. Install the nuts and 30mm (1.18 in) bolts. Tighten to 13 ft. lbs. (18 Nm).
  126.  
  127. Install the fuel injectors and the delivery pipes.
  128.  
  129. Install the fuel return pipe. Tighten the union bolt at the pressure regulator to 26 ft. lbs. (35 Nm).
  130.  
  131. Connect the engine wiring harness to the rear water bypass joint. On California vehicles, connect the harness connectors.
  132.  
  133. Connect the injector connectors to the injectors. Connect the wiring connectors to the left delivery pipe. Install the harness protector.
  134.  
  135. Install the engine wiring to the intake manifold.
  136.  
  137. Install the wire harness brackets onto the right cylinder head. Secure the harness to the brackets and install the protector.
  138.  
  139. Connect the fuel return hose to the return pipe; connect the fuel inlet hose to the left delivery pipe. Always use new gaskets. Using a torque wrench with a fulcrum length of 30mm (11.81 in), tighten the union bolt at the pulsation damper to 29 ft. lbs. (39 Nm).
  140.  
  141. Connect the heater hoses.
  142.  
  143. Install the air intake chamber.
  144.  
  145. Before installing the throttle body, place a new gasket in position on the air intake chamber. Install the throttle body. Use the 40mm (1.57 in) bolts and tighten them to 13 ft. lbs. (18 Nm). Connect the water bypass pipe to the clamp on the wire cover. Connect the electrical connectors to the throttle body.
  146.  
  147. Install the IAC valve. Tighten the bolts to 13 ft. lbs. (18 Nm). Install the hoses and attach the connectors.
  148.  
  149. Install the EGR valve adapter with a new gasket. Do not touch the contact faces of the gasket with your fingers. Tighten the bolts to 13 ft. lbs. (18 Nm). Connect the PCV hose and attach the wiring connector
  150.  
  151. Install the EGR valve with a new gasket. Do not touch the contact faces of the gasket with your fingers. Double check the alignment of the gasket. Tighten the bolts to 13 ft. lbs. (18 Nm). Connect the coolant hoses to the IAC valve and to the bypass pipe.
  152.  
  153. Install the vacuum pipe and hose assembly and install the EGR water bypass pipe. Connect the vacuum hoses removed prior.
  154.  
  155. Install the timing belt rear plates.
  156.  
  157. Install the water inlet and inlet housing. Make sure the contact faces are clean and that new sealant is applied to the sealing groove of the inlet housing. Alternately and gradually, tighten the bolts to 13 ft. lbs. (18 Nm). Connect the coolant hoses.
  158.  
  159. Install the right ignition coil.
  160.  
  161. Connect the accelerator cable, the transmission throttle control cable and the cruise control cable to the throttle body.
  162.  
  163. Install the throttle body cover.
  164.  
  165. Install the front catalytic converters.
  166.  
  167. Install the front exhaust pipe.
  168.  
  169. Install the power steering pump. Tighten the bolts to 29 ft. lbs. (39 Nm) and the nuts to 32 ft. lbs. (43 Nm). Install the power steering pump pulley; tighten the nut to 32 ft. lbs. (43 Nm). Connect the air hose to the air intake chamber.
  170.  
  171. Install the fan bracket.
  172.  
  173. Install the right camshaft timing pulley. The R mark must face forward. Install the pulley bolt; tighten it to 80 ft. lbs. (108 Nm).
  174.  
  175. Install the left camshaft timing pulley. The L mark must face forward. Install the pulley bolt; tighten it to 80 ft. lbs. (108 Nm).
  176.  
  177. Install the timing belt.
  178.  
  179. Connect the negative battery terminal.
  180.  
  181. Refill the engine with coolant.
  182.  
  183. Start the engine and check for leaks. Check the ignition timing and other engine settings.
  184.  
  185. Road test the vehicle.
  186.  
  187. Install the engine undercovers.
  188.  

Specific to:

Lexus LS400 1990-1992, 1995-1999

  1. Disconnect timing belt from camshaft timing pulleys.
  2.  
  3. Remove camshaft timing pulleys
  4.  
  5. Remove camshaft position sensor
  6.  
  7. Disconnect ps pump from engine
  8.  
  9. Disconnect front exhaust pipe from TWC
    1. Remove the 4 bolts and 4 nuts holding the front exhaust pipe to the TWC.
    2.  
    3. Disconnect the front exhaust pipe from the 2 TWC, and remove the 2 gaskets.
    4.  
    5. Remove the 2 bolts and pipe support bracket.
    6.  

  10.  
  11. Remove TWC
    1. Remove the 3 nuts, TWC and gasket. Remove the 2 TWC.
    2.  

  12.  
  13. Remove ignition coils.
  14.  
  15. Remove timing belt rear plates
    1. Remove the 3 bolts, stud bolt, and RH No.1 and No.2 timing belt rear plates.
    2.  
    3. Disconnect the wire clamp from the LH timing belt rear plate.
    4.  
    5. Remove the 3 bolts, LH No.1 and No.2 timing belt rear plates.
      NOTE
      Be careful not to drop anything inside the timing belt cover.


      NOTE
      Do not allow the belt to come into correct with oil, water or dust.

    6.  

  16.  
  17. Disconnect fuel inlet hose
  18.  
  19. Remove intake manifold assembly
    1. Disconnect the accelerator cable.
    2.  
    3. Disconnect the throttle position sensor connector.
    4.  
    5. Disconnect the accelerator pedal position sensor connector.
    6.  
    7. Disconnect the throttle motor connector.
    8.  
    9. Disconnect the VSV connector for EVAP.
    10.  
    11. Disconnect the VSV connector for ACIS.
    12.  
    13. Disconnect the 8 injector connectors.
    14.  
    15. Disconnect the noise filter connector.
    16.  
    17. Disconnect the brake booster vacuum hose from the union on the intake manifold.
    18.  
    19. Disconnect the PCV hose from the PCV valve on the LH cylinder head.
    20.  
    21. Disconnect the EVAP hose (from the charcoal canister) from the VSV for EVAP.
    22.  
    23. Disconnect the EVAP hose (from the charcoal canister) from the EVAP pipe on the intake manifold.
    24.  
    25. Disconnect the EVAP hose (from the intake air connector) from the EVAP pipe on the intake manifold.
    26.  
    27. Disconnect the PS air hose from the intake manifold.
    28.  
    29. Disconnect the No.1 water bypass hose (from the water inlet housing) from the throttle body.
    30.  
    31. Disconnect the No.7 water bypass hose (from the front water bypass joint) from the throttle body.
    32.  
    33. Disconnect the 2 wire clamp from the throttle body.
    34.  
    35. Remove the 2 bolts and EVAP pipe from the intake manifold.
    36.  
    37. Remove the 2 nuts and accelerator cable bracket.
    38.  
    39. Disconnect the VSV connector for ACIS from the No.1 V-bank cover bracket.
    40.  
    41. Remove the 4 bolts and 3 V-bank cover brackets.
    42.  
    43. Remove the bolt and VSV for EVAP.
    44.  
    45. Disconnect the engine wire from the RH delivery pipe, rear water bypass joint, intake manifold and cylinder head.

      Disconnect the 2 wire clamps from the wire clamp bracket on the RH delivery pipe.
       
      Remove the 3 bolts, and disconnect the engine wire protector from the rear water bypass joint and RH cylinder head.
       
      Remove the 3 bolts, and disconnect the engine wire protector and wire clamp bracket from the intake manifold.
       

    46.  
    47. Remove the 6 bolts, 4 nuts, intake manifold assembly and 2 gaskets.
    48.  

  20.  
  21. Remove water inlet and inlet housing assembly
  22.  
  23. Remove front water bypass joint
    1. Disconnect the ECT sensor connector.
    2.  
    3. Remove the 4 nuts, water bypass joint and 2 gaskets.
    4.  

  24.  
  25. Remove rear water bypass joint
    1. Remove the 4 nuts, water bypass joint and 2 gaskets.
    2.  

  26.  
  27. Remove VVT sensors
  28.  
  29. Remove engine hangers
  30.  
  31. Remove oil dipstick and guide for A/T
  32.  
  33. Remove oil dipstick and guide for engine
  34.  
  35. Remove cylinder head covers
    1. Remove the 9 bolts, 9 seal washers, cylinder head cover and gasket. Remove the 2 cylinder head covers.
    2.  

  36.  
  37. If necessary, remove semi-circular plugs and camshaft housing plugs
  38.  
  39. Remove camshaft timing oil control valve
  40.  
  41. Remove camshafts
    NOTE
    Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. 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.

    1. Check the crankshaft pulley position. Check that the timing mark of the crankshaft pulley is in aligned with the centers of the rankshaft pulley bolt and idler pulley bolt.
      NOTE
      Having the crankshaft pulley at the wrong angle can cause the piston head and valve head to come into contact with each other when you remove the camshaft, causing damage. So always set the crankshaft pulley at the correct angle.

    2.  
    3. Rotate the VVT-i pulley from left to right 2 to 3 times within its range of movement (25° <50° CA> ) and use a waste cloth to collect the oil from the camshaft timing oil control valve installation hole.
      NOTE
      Approximately 20 cc (1.2 cu in.) of oil will be ejected, so take care not to spill it.

    4.  
    5. Remove the RH camshafts.
      NOTE
      When removing the camshafts, make sure that the torsional spring force of the sub-gear has been eliminated by the above operation.



      Boring the service bolt hole of the sub-gear upward by turning the hexagon wrench head portion of the exhaust camshaft with a wrench.
       
      Secure the sub-gear to the main gear with a service bolt.
       



      Set the timing mark (1 dot mark) of the camshaft main gear at approx. 10° angle by turning the hexagon wrench head portion of the exhaust camshaft with a wrench.
       
      Uniformly loosen and remove the 22 bearing cap bolts in several passes, in the sequence shown.

      Click image to see an enlarged view

      Fig. Uniformly loosen and remove the RH 22 bearing cap bolts in several passes in the sequence shown

       
      Remove the oil feed pipe, 9 bearing caps, cam shaft timing oil control valve and camshafts.
       

    6.  
    7. Remove the LH camshafts.
      NOTE
      When removing the camshaft, make sure that the torsional spring force of the sub-gear has been eliminated by the above operation.


      NOTE
      Arrange the bearing caps in correct order.



      Boring the service bolt hole of the sub-gear upward by turning the hexagon wrench head portion of the exhaust camshaft with a wrench.
       
      Secure the sub-gear to the main gear with a service bolt.
       



      Align the timing mark (2 dot marks) of the camshaft drive gear by turning the hexagon wrench head portion of the exhaust camshaft with a wrench.
       
      Uniformly loosen and remove the 22 bearing cap bolts in several passes, in the sequence shown.

      Click image to see an enlarged view

      Fig. Uniformly loosen and remove the LH 22 bearing cap bolts in several passes in the sequence shown

       
      Remove the oil feed pipe, 9 bearing caps, cam shaft timing oil control valve filter and camshafts.
       

    8.  

  42.  
  43. Disassemble exhaust camshafts
    1. Mount the hexagon wrench head portion of the camshaft in a vise.
      NOTE
      Be careful not to damage the camshaft.

    2.  
    3. Using SST (SST 09960-10010 (09962-01000, 09963-00500), turn the sub-gear clockwise, and remove the service bolt.
    4.  
    5. Using snap ring pliers, remove the snap ring.
    6.  
    7. Remove the wave washer.
    8.  
    9. Remove the camshaft sub-gear.
    10.  
    11. Remove the camshaft gear spring.
      NOTE
      Arrange the camshaft sub-gears and gear spring (RH and LH sides).

    12.  

  44.  
  45. Remove cam shaft timing tubes
    1. Mount the hexagon wrench head portion of the intake camshaft in a vise.
      NOTE
      Be careful not to damage the camshaft.


      NOTE
      The 4 bolts shown in the illust ration determine the backlash of the gear in the timing tube, so do not remove them. If any of the 4 bolts are removed, install a new camshaft timing tube assembly.

    2.  
    3. Remove the straight screw plug and seal washer.
    4.  
    5. Using a 10 mm hexagon wrench, and remove the set bolt and camshaft timing tube.
    6.  
    7. Using a 5 mm hexagon wrench, and remove the 4 bolts, camshaft drive gear and oil seal.
      NOTE
      Be careful not to damage the camshaft timing tube.

    8.  

  46.  
  47. Remove spark plugs
  48.  
  49. Remove cylinder head and exhaust manifold Assemblies
    1. Disconnect the 2 heated oxygen sensor connectors.
    2.  
    3. Remove the bolt, and disconnect the ground cable from the RH cylinder head.
    4.  
    5. Remove the bolt, and disconnect the ground cable from the LH cylinder head.
    6.  
    7. Remove the bolt, and disconnect the engine wire protector from the LH cylinder head.
    8.  
    9. Uniformly loosen the 10 cylinder head bolts on one side of each cylinder head in several passes, then do the other side. Remove the 20 cylinder head bolts and plate washers.
      NOTE
      Cylinder head warpage or cracking could result from removing bolts in incorrect order.


      NOTE
      Do not drop the plate washer for cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan.



      Click image to see an enlarged view

      Fig. Uniformly loosen the 10 cylinder head bolts on one side of each cylinder head in several passes in the sequence shown



      Click image to see an enlarged view

      Fig. Cylinder head plate washers location

    10.  
    11. Lift the cylinder head from the dowels on the cylinder block, and place the 2 cylinder heads on wooden blocks on a bench.
      NOTE
      If the cylinder head is lift off, pry between the cylinder head and cylinder block with a screwdriver.


      NOTE
      Be careful not to damage the contact surfaces of the cylinder head and cylinder block.


      NOTE
      The cylinder head should not be tilted so as to secure the valve lifter. If the cylinder head is tilted, remove the valve lifter and check that the adjusting shim is set correctly.

    12.  

  50.  
  51. Remove RH exhaust manifold from cylinder head.
    1. Remove the 3 bolts and heat insulator.
    2.  
    3. Remove the 8 nuts, exhaust manifold and gasket.
    4.  

  52.  
  53. Remove LH exhaust manifold from cylinder head
    1. Remove the 3 bolts and heat insulator.
    2.  
    3. Remove the 8 nuts, exhaust manifold and gasket.

      Click image to see an enlarged view

      Fig. Cylinder head components (1 of 6)



      Click image to see an enlarged view

      Fig. Cylinder head components (2 of 6)



      Click image to see an enlarged view

      Fig. Cylinder head components (3 of 6)



      Click image to see an enlarged view

      Fig. Cylinder head components (4 of 6)



      Click image to see an enlarged view

      Fig. Cylinder head components (5 of 6)



      Click image to see an enlarged view

      Fig. Cylinder head components (6 of 6)

    4.  

  54.  

To install:

  1. Install RH exhaust manifold to cylinder head
    1. Place a new gasket on the cylinder head with the white painted marks facing the manifold side.
      NOTE
      Be careful of the installation direction.

    2.  
    3. Install the exhaust manifold with 8 new nuts. Uniformly tighten the nuts in several passes. Tighten the nuts to 32 ft. lbs. 44 Nm).
    4.  
    5. Install the heat insulator with the 3 bolts.
    6.  

  2.  
  3. Install LH exhaust manifold to cylinder head
    1. Place a new gasket on the cylinder head with the white painted marks facing the manifold side.
      NOTE
      Be careful of the installation direction.

    2.  
    3. Install the exhaust manifold with 8 new nuts. Uniformly tighten the nuts in several passes. Tighten the nuts to 32 ft. lbs. (44 Nm).
    4.  
    5. Install the heat insulator with the 3 bolts.
    6.  

  4.  
  5. Place cylinder head on cylinder block
    1. Place 2 new cylinder head gaskets in position on the cylinder block.
      NOTE
      On the rear side of the cylinder head gasket are marks to distinguish the LH and RH banks, a -R- mark for the RH bank and a -L- mark for the LH bank.


      NOTE
      Be careful of the installation direction.

    2.  
    3. Place the 2 cylinder heads in position on the cylinder head gaskets.
    4.  

  6.  
  7. Install cylinder head bolts
    NOTE
    The cylinder head bolts are tightened in 2 progressive steps (steps (c) and (e)).


    NOTE
    If any cylinder head bolt is broken or deformed, replace it.

    1. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
    2.  
    3. Install the plate washer to the cylinder head bolt.
    4.  
    5. Install and uniformly tighten the 10 cylinder head bolts on one side of the cylinder head in several passes, then do the other side. Tighten the bolts to 29 ft. lbs. (39 Nm). If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt.
      NOTE
      Do not drop the plate washer for cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan.

    6.  
    7. Mark the front of the cylinder head bolt head with paint.
    8.  
    9. Retighten the cylinder head bolts by 90° in the numerical order shown.
    10.  
    11. Check that the painted mark is now at a 90° angle to front.

      Click image to see an enlarged view

      Fig. Cylinder head bolt installation and tightening order

    12.  

  8.  
  9. Install engine wire
    1. Install the ground cable to RH cylinder head with the bolt.
    2.  
    3. Install the engine wire protector to the LH cylinder head with the bolt.
    4.  
    5. Install the ground cable to LH cylinder head with the bolt.
    6.  
    7. Connect the 2 heated oxygen sensor connectors.
    8.  

  10.  
  11. Install spark plugs
  12.  
  13. Assemble exhaust camshaft
    1. Install the camshaft gear spring.
    2.  
    3. Install the camshaft sub-gear.
      NOTE
      Attach the pins on the gears to the gear spring ends.

    4.  
    5. Install the wave washer.
    6.  
    7. Using snap ring pliers, install the snap ring.
    8.  
    9. Mount the hexagon wrench head portion of the camshaft in a vise.
      NOTE
      Be careful not to damage the camshaft.

    10.  
    11. Using SST (SST 09960-10010 (09962-01000, 09963-00500), align the holes of the camshaft main gear and sub-gear by turning camshaft sub-gear counterclockwise, and temporarily install a service bolt.
    12.  
    13. Align the gear teeth of the main gear and sub-gear, and tighten the service bolt.
    14.  

  14.  
  15. Install camshaft timing tubes
    1. Place a new oil seal to the timing tube.
      NOTE
      Be careful installation direction.

    2.  
    3. Align the timing tube knock pin with the knock pin groove of the camshaft drive gear, and temporarily install the camshaft drive gear with the 4 bolts.
    4.  
    5. Using a 5 mm hexagon wrench, uniformly tighten the 4 bolts. Tighten the bolts to 66 inch lbs. (7.5 Nm).
      NOTE
      Be careful not to damage the camshaft timing tube.

    6.  
    7. Mount the hexagon wrench head portion of the intake camshaft in a vise.
      NOTE
      Be careful not to damage the camshaft.

    8.  
    9. Align the camshaft knock pin with the camshaft timing tube, and push the camshaft timing tube by hand until you feel it touch the bottom.
    10.  
    11. Using a 10 mm hexagon wrench, install the set bolt. Tighten the bolt to 58 ft. lbs. (78 Nm).
    12.  
    13. Install the seal washer and straight screw plug. Tighten the screw plug to 132 inch lbs. (15 Nm).
    14.  

  16.  
  17. Install camshaft housing plugs
    1. Remove any old packing (FIPG) material.
    2.  
    3. Apply seal packing to the camshaft housing plug grooves. Seal packing: Part No. 08826-00080 or equivalent
    4.  
    5. Install the 2 camshaft housing plugs to the cylinder heads.
    6.  

  18.  
  19. Install camshafts
    NOTE
    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.

    1. Set the crankshaft pulley position. Turn the crankshaft pulley clockwise or counterclockwise, and put the timing mark of the crankshaft pulley in line with the centers of the crankshaft pulley bolt and idler pulley bolt.
      NOTE
      Having the crankshaft pulley at the wrong angle can cause the piston head and valve head to come into contact with each other when you install the camshaft, causing damage. So always set the crankshaft pulley at the correct angle.

    2.  
    3. Install the RH camshafts.
      NOTE
      Be careful installation direction.


      NOTE
      Install a nozzle that has been cut to a 0.06 in. (1.5 mm) opening.


      NOTE
      Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.


      NOTE
      Immediately remove nozzle from the tube and reinstall cap.


      NOTE
      Do not apply seal packing to the front bearing cap grooves.


      NOTE
      Installing the front bearing cap will determine the thrust portion of the camshaft.


      NOTE
      Align the arrow marks at the front and rear of the cylinder head with the mark on the bearing cap.


      NOTE
      Do not apply engine oil under the heads of the bearing cap bolt (A), (B), and (C).



      Apply MP grease to the thrust portion of the intake and exhaust camshafts.
       
      Place the intake and exhaust camshafts.
       
      Set the timing mark (1 dot mark) of the camshaft main gear at approx. 10° angle.
       
      Place the camshaft oil control valve filter to the cylinder head.
       



      Remove any old packing (FIPG) material from front bearing cap.
       
      Apply seal packing to the front bearing cap. Seal packing: Part No. 08826-00080 or equivalent
       



      Install the front bearing cap.
       



      Install the other bearing cap in the sequence shown with the arrow mark facing forward.
       



      Push in the camshaft oil seal.
       
      Apply a light coat of engine oil on the threads and under the heads (D and E) of the bearing cap bolts.
       



      Install the oil feed pipe and the 22 bearing cap bolts.

      Click image to see an enlarged view

      Fig. Bearing cap bolts. Each bolt is indicated in the graphic. Bolt lengths: (A - 3.70 inch (94 mm), (B - 2.83 inch (72 mm), (C - 0.98 inch (25 mm), (D - 2.05 inch (52 mm), (E - 1.50 inch (38 mm)

       
      Uniformly tighten the 22 bearing cap bolts in several passes. Torque: Bolt C: 66 inch lbs. (7.5 Nm), all others: 144 inch lbs. (16 Nm).

      Click image to see an enlarged view

      Fig. Bearing cap bolts tightening sequence

       
      Boring the service bolt installed in the driven sub-gear upward by turning the hexagon wrench head portion of the camshaft with a wrench.
       
      Remove the service bolt.
       

    4.  
    5. Install the LH camshafts.
      NOTE
      Be careful installation direction.


      NOTE
      Install a nozzle that has been cut to a 0.06in. (1.5 mm) opening.


      NOTE
      Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.


      NOTE
      Immediately remove nozzle from the tube and reinstall cap.


      NOTE
      Do not apply seal packing to the front bearing cap grooves.


      NOTE
      Installing the front bearing cap will determine the thrust portion of the camshaft.


      NOTE
      Align the arrow marks at the front and rear of the cylinder head with the mark on the bearing cap.


      NOTE
      Do not apply engine oil under the heads of the bearing cap bolts.



      Apply MP grease to the thrust portion of the intake and exhaust camshafts.
       
      Place the intake and exhaust camshafts.
       
      Engage the intake to the exhaust gear by meeting the timing marks (2 dot marks) on each gear.
       
      Place the camshaft oil control valve filter to the cylinder head.
       



      Remove any old packing (FIPG) material.
       
      Apply seal packing to the front bearing cap. Seal packing: Part No. 08826-00080 or equivalent
       



      Install the front bearing cap.
       



      Install the other bearing cap with the arrow mark facing forward.
       



      Push in the camshaft oil seal.

      Click image to see an enlarged view

      Fig.

       
      Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
       



      Install the oil feed pipe and the 22 bearing cap bolts
       
      Uniformly tighten the 22 bearing cap bolts in several passes, in the sequence shown. Tighten Bolt C: 66 inch lbs. (7.5 Nm), all others: 144 inch lbs. (16 Nm).

      Click image to see an enlarged view

      Fig. Uniformly tighten the 22 bearing cap bolts in several passes, in the sequence shown

       
      Boring the service bolt installed in the driven sub-gear upward by turning the hexagon wrench head portion of the camshaft with a wrench.
       
      Remove the service bolt.
       

    6.  

  20.  
  21. Check and adjust valve clearance
    1. Turn the camshaft and position the cam lobe upward, and check and adjust the valve clearance.
    2.  

  22.  
  23. Install semi-circular plugs
    1. Remove any old packing (FIPG) material.
    2.  
    3. Apply seal packing to the semi-circular plug grooves. Seal packing: Part No. 08826-00080 or equivalent
    4.  
    5. Install the 4 semi-circular plugs to the cylinder heads.
    6.  

  24.  
  25. Install cylinder head cover
    1. Remove any old packing (FIPG) material.
    2.  
    3. Apply seal packing to the cylinder heads. Seal packing: Part No. 08826-00080 or equivalent
    4.  
    5. Install the gasket to the cylinder head cover.
    6.  
    7. Install the seal washer to the bolt.
    8.  
    9. Install the cylinder head cover with the 9 bolts. Uniformly tighten the bolts in several passes. Install the 2 cylinder head covers. Tighten the bolts to 53 inch lbs. (6.0 Nm).
    10.  

  26.  
  27. Install engine hangers. Tighten the hangers to 27 ft. lbs. (37 Nm).
  28.  
  29. Install VVT sensors.
  30.  
  31. Install camshaft timing oil control valve
  32.  
  33. Install oil dipstick and guide for engine
  34.  
  35. Install oil dipstick and guide for A/T
  36.  
  37. Install rear water bypass joint
    1. Install 2 new gaskets to the cylinder head.
    2.  
    3. Install the 4 nuts holding the water bypass joint to the cylinder heads. Alternately tighten the nuts. Tighten nuts to 13 ft. lbs. (18 Nm).
    4.  

  38.  
  39. Install front water bypass joint
    1. Install 2 new gaskets and the water bypass joint with the 4 nuts. Alternately tighten the nuts. Tighten nuts to 13 ft. lbs. (18 Nm).
    2.  
    3. Connect ECT sensor connector.
    4.  

  40.  
  41. Install water inlet and inlet housing assembly
  42.  
  43. Install intake manifold assembly
    1. Place 2 new gaskets on the cylinder heads with white painted mark facing upward.
      NOTE
      Align the port holes of the gasket and cylinder head.


      NOTE
      Be careful of the installation direction.

    2.  
    3. Place the intake manifold assembly on the cylinder heads.
    4.  
    5. Install and uniformly tighten the 6 bolts and 4 nuts in several passes. Tighten nuts to 13 ft. lbs. (18 Nm).
    6.  
    7. Connect the engine wire to the RH delivery pipe, rear water bypass joint, intake manifold and RH cylinder head.

      Connect the wire clamp bracket and wire protector to the intake manifold with the 3 bolts.
       
      Connect the wire protector to the rear water bypass joint and RH cylinder head with the 3 bolts.
       
      Connect the 2 wire clamp to the wire clamp bracket on the RH delivery pipe.
       

    8.  
    9. Install the 3 V-bank cover brackets with the 4 bolts. Tighten the bolts to 66 inch lbs. (7.5 Nm).
    10.  
    11. Connect the VSV connector for ACIS to the No.1 V-bank cover bracket.
    12.  
    13. Install the accelerator cable bracket with the 2 nuts. Tighten the nuts to 13 ft. lbs. (18 Nm).
    14.  
    15. Install the VSV for EVAP with the bolt. Tighten the bolt to 13 ft. lbs. (18 Nm).
    16.  
    17. Install the EVAP pipe to the intake manifold with the 2 bolts.
    18.  
    19. Connect the brake booster vacuum hose to the union on the intake manifold.
    20.  
    21. Connect the PCV hose to the PCV valve on the LH cylinder head.
    22.  
    23. Connect the EVAP hose (from the charcoal canister) to the VSV for EVAP.
    24.  
    25. Connect the EVAP hose (from the charcoal canister) to the EVAP pipe on the intake manifold.
    26.  
    27. Connect the EVAP hose (from the intake air connector) to the EVAP pipe on the intake manifold.
    28.  
    29. Connect the PS air hose to the intake manifold.
    30.  
    31. Connect the No.1 water bypass hose (from the water inlet housing) to the throttle body.
    32.  
    33. Connect the No.7 water bypass hose (from the front water bypass joint) to the throttle body.
    34.  
    35. Connect the 2 wire clamp to the throttle body.
    36.  
    37. Connect the throttle position sensor connector.
    38.  
    39. Connect the accelerator pedal position sensor connector.
    40.  
    41. Connect the throttle motor connector.
    42.  
    43. Connect the VSV connector for EVAP.
    44.  
    45. Connect the VSV connector for ACIS.
    46.  
    47. Connect the 8 injector connectors.
    48.  
    49. Connect the noise filter connector.
    50.  
    51. Connect the accelerator cable.
    52.  

  44.  
  45. Connect fuel inlet hose.
  46.  
  47. Install timing belt rear plates
    1. Install the RH timing belt rear plates.

      Install the No.1 timing belt rear plate to the cylinder head with the bolt and stud bolt. Tighten the bolt to 66 inch lbs. (7.5 Nm).
       
      install the No.2 timing belt rear plate to the No.1 timing belt rear plate with the 2 bolts. Tighten the bolts to 66 inch lbs. (7.5 Nm).
       

    2.  
    3. Install the LH timing belt rear plates.

      Connect the wire clamp to the No.1 timing belt rear plate.
       
      Install the No.1 timing belt rear plate to the cylinder head with the bolt. Tighten the bolt to 66 inch lbs. (7.5 Nm).
       
      install the No.2 timing belt rear plate to the No.1 timing belt rear plate with the 2 bolts. Tighten the bolts to 66 inch lbs. (7.5 Nm).
       

    4.  

  48.  
  49. Install ignition coils.
  50.  
  51. Install TWC
    1. Install a new gasket and the TWC with 3 new nuts. Install the 2 TWC. Tighten the nuts to 46 ft. lbs. (61.8 Nm).
    2.  

  52.  
  53. Connect front exhaust pipe to TWC.
    1. Temporarily install the pipe support bracket to the transmission with the 2 bolts.
    2.  
    3. Install a new gasket to each rear end of the TWC.
    4.  
    5. Connect the front exhaust pipe to the 2 front TWC and pipe support bracket with the 4 bolts and 4 new nuts. Tighten the bolts to 32 ft. lbs. (43 Nm).
    6.  
    7. Tighten the 2 bolts holding the pipe support bracket to the transmission. Tighten the bolts to 32 ft. lbs. (43.1 Nm).
    8.  

  54.  
  55. Install PS pump.
  56.  
  57. Install camshaft position sensor.
  58.  
  59. Install camshaft timing pulleys.
  60.  
  61. Connect timing belt to camshaft timing pulleys.
  62.  
  63. Check engine oil level.
  64.  

 
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