Cylinder Head

REMOVAL & INSTALLATION

3000GT

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Relieve fuel system pressure.
3. Disconnect the negative battery cable.
4. Drain the cooling system.
5. Remove or disconnect the following:
   • Air intake hoses
   • Air intake plenum and intake manifold
   • Turbocharger, if equipped
   • Exhaust manifold
   • Timing belt
   • Triple pipe assembly across the top of the engine
   • Breather hose
   • Spark plug wire center cover and remove the spark plug wires

   NOTE: When removing the valve cover, note that bolts for the front head cover are black and bolts for the rear head cover are green. All bolts are 10mm long except for the one closest to the sprockets on the rear head, which is 20mm long.

6. For SOHC engine, remove the camshaft sprockets. For DOHC engines, remove the intake camshaft sprockets.
7. Remove or disconnect the following:
   • Rear timing belt cover
   • Ignition coil
   • All water hoses from the thermostat housing
   • Thermostat housing
   • Water inlet from the front head and discard O-ring
8. Loosen the cylinder head mounting bolts in 3 steps, starting from the outside and working inward. Lift off the cylinder head assembly and remove the head gasket.

   To install:

9. Thoroughly clean the sealing surfaces of the head and block.
10. Place a new head gasket on the cylinder block with the identification marks in the front top (upward) position. Do not use sealer on the gasket.
11. Carefully install the cylinder head on the block. Be sure the head bolt washers are installed with the chamfered edge upward.
12. Using 3 even steps, torque the head bolts in sequence, to 76–83 ft. lbs. (105–115 Nm) for non-turbocharged engine or 87–94 ft. lbs. (120–130 Nm) for turbocharged engine.
13. On turbocharged models, loosen all cylinder head bolts and retighten in sequence to 87–94 ft. lbs. (120–130 Nm).
14. Install or connect the following:
    • New O-ring and connect the water inlet to the front head
    • Gaskets and install the thermostat housing and connect the hoses
    • Ignition coil and the rear timing belt cover
15. For SOHC engine, install the camshaft sprockets. For DOHC engines, install the intake camshaft sprockets. Tighten the retaining bolt to 65 ft. lbs. (90 Nm).
16. Apply sealer to the lower edges of the half-round portions of the belt-side of the new gasket and install the valve cover. Tighten the bolts in the proper sequence to 26 inch lbs. (3 Nm). Then, retighten bolts Nos. 1–6 to 35 inch lbs. (4 Nm).
17. Install or connect the following:
    • Spark plug wires and install the center cover
    • Breather hose
    • Triple pipe assembly across the top of the engine and tighten the retaining bolts to 84 inch lbs. (10 Nm).
    • Timing belt
    • Intake manifold, air intake plenum, turbocharger and exhaust manifold, using new gaskets
    • Air intake hoses
18. Fill the system with coolant.
19. Adjust the accelerator cable. Check and adjust the idle speed and ignition timing.
20. Once the vehicle has cooled, recheck the coolant level.

Diamante

3.0L DOHC ENGINE

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Relieve fuel system pressure. Disconnect the negative battery cable.
3. Drain the cooling system.
4. Remove or disconnect the following:
   • Air intake hoses
   • Air intake plenum and intake manifold
   • Exhaust manifold
   • Timing belt
   • Breather hose
   • Spark plug wire center cover and remove the spark plug wires
   • Rocker covers
   • Intake camshaft sprockets
   • Rear timing belt cover
   • Ignition coil assembly
   • Water hoses from the thermostat housing
   • Thermostat housing
   • Water inlet from the front head
5. Loosen the cylinder head mounting bolts in the reverse of the torque sequence and loosen the bolts in 3 steps. Lift off the cylinder head assembly and remove the head gasket.

   To install:

6. Thoroughly clean the sealing surfaces of the head and block.
7. Place a new head gasket on the cylinder block with the identification marks in the front top (upward) position. Do not use sealer on the gasket.
8. Carefully install the cylinder head on the block. Be sure the head bolt washers are installed with the chamfered edge upward. Using 3 even steps, torque the head bolts in sequence, to 76–83 ft. lbs. (105–115 Nm).

   Fig. 1: Rocker cover bolt torque sequence — Diamante 3.0L DOHC engine

9. Install new O-ring and connect the water inlet to the head. Tighten the mounting bolt to 10 ft. lbs. (13 Nm).
10. Replace the gaskets and install the thermostat housing. Tighten the mounting bolts to 12–14 ft. lbs. (17–20 Nm).
11. Install or connect the following:
    • Hoses to the thermostat housing, using new clamps
    • Ignition coil and torque the mounting bolts to 84 inch lbs. (10 Nm)
    • Rear timing belt cover and torque the mounting bolts to 17 ft. lbs. (24 Nm)
    • Intake camshaft sprockets. Tighten the retaining bolt to 65 ft. lbs. (90 Nm).
12. Apply sealer to the lower edges of the valve cover. Tighten the bolts in the proper sequence to 44–51 inch lbs. (5–6 Nm).
13. Install or connect the following:
    • Spark plug wires and install the center cover. Tighten the bolts that secure the center cover to 27 inch lbs. (3 Nm)
    • Breather hose
    • Timing belt
    • Exhaust manifold assembly
    • Intake manifold and air intake plenum, using all new gaskets
    • Air intake hoses
14. Change the engine oil and oil filter.
15. Fill the system with coolant.
16. Connect the negative battery cable.
17. Adjust the accelerator cable. Start the engine. Check and adjust the idle speed and ignition timing.
18. Once the vehicle has cooled, recheck the coolant level.

3.0L SOHC ENGINE

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Relieve the fuel system pressure. Disconnect the negative battery cable.
3. Drain the cooling system.
4. Remove or disconnect the following:
   • Air intake hose
   • Exhaust manifold
   • Air intake plenum and intake manifold
   • Timing belt
   • Camshaft sprockets and the rear timing belt cover
   • Power steering pump bracket. If removing the rear head, remove the alternator brace.
   • Water inlet pipe
   • Purge pipe assembly
   • Valve cover
5. Using the reverse sequence of the installation sequence, loosen the cylinder head mounting bolts in 3 steps. Lift off the cylinder head assembly and remove the head gasket.

   To install:

6. Thoroughly clean the sealing surfaces of the head and block.
7. Place a new head gasket on the cylinder block making sure the identification mark on the cylinder head gasket is in the front top (upward) location. Do not use sealer on the gasket.
8. Carefully install the cylinder head on the block. Be sure the head bolt washers are installed with the chamfered edge upward. Using 3 even steps, torque the head bolts in sequence, to 76–83 ft. lbs. (105–115 Nm).
9. Apply sealer to the lower edges of the half-round portions and install the valve cover. Tighten valve cover bolts to 84 inch lbs. (9 Nm).
10. Install or connect the following:
    • Purge pipe assembly
    • Water inlet pipe
    • Power steering pump bracket and alternator brace
    • Rear timing belt cover and camshaft sprockets. Torque the retaining bolt to 65 ft. lbs. (90 Nm).
    • Timing belt
    • Intake manifold, air intake plenum and exhaust manifold, using new gaskets
    • Air intake hose
11. Fill the system with coolant.
12. Connect the negative battery cable.
13. Start the engine.
14. Check and adjust the idle speed and ignition timing.
15. Once the vehicle has cooled, recheck the coolant level.

3.5L ENGINE

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Disconnect the negative battery cable.
3. Drain the engine coolant
4. Remove or disconnect the following:
   • Timing belt
   • Intake and exhaust manifolds
   • Spark plug wires
   • Cylinder head covers
   • Timing belt rear center cover
5. Loosen the cylinder head bolts gradually in 3 stages, in the opposite of the installation sequence.
6. Remove the cylinder head.

   To install:

7. Clean the cylinder head and mounting surface on the engine block.
8. Install the cylinder head using a new gasket.
9. Tighten the bolts in sequence using 3 stages to 76–83 ft. lbs. (103–113 Nm).
10. Install or connect the following:
    • Timing belt rear center cover
    • Cylinder head covers using new gaskets. Tighten the bolts to 24–36 inch lbs. (3–4 Nm).
    • Spark plug wires
    • Intake and exhaust manifolds
    • Timing belt
    • Remaining components
11. Refill the cooling system.
12. Connect the negative battery cable.

Eclipse

2.0L (4G63) ENGINE

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Relieve the fuel system pressure.
3. Disconnect the negative battery cable.
4. Drain the engine coolant.
5. Remove or disconnect the following:
   • Accelerator cable and remove the mounting bracket
   • Intake air duct (hose) from the throttle body
6. Disconnect the following connectors:
   • IAC motor
   • Knock sensor
   • HO2S sensor
   • ECT gauge sender
   • ECT sensor
   • Ignition module (power transistor)
   • TP sensor
   • Condenser
   • MAP sensor
   • Injectors
   • Ignition coil
   • CMP sensor
   • CKP sensor
   • air conditioning compressor
   • Engine control wiring harness
7. Remove or disconnect the following:
   • Engine center cover
   • Spark plug wires
   • Brake booster vacuum hose
   • Fuel lines from the fuel supply rail
   • Bypass hose and the water hose connections
   • Vacuum hoses, breather hose and the PCV hose
   • Timing belt
   • Power steering pump
   • Cylinder head cover and the semi-circular packing
   • Heat protector
8. Mark the position of the hose clamps on the hoses and disconnect the water hoses and the radiator hoses.
9. Remove or disconnect the following:
   • Thermostat housing and the O-ring
   • Intake manifold stay
   • Turbocharger assembly from the exhaust manifold
10. Gradually loosen the cylinder head bolts in 2 or 3 steps using the specified sequence and remove the bolts.

    Fig. 2: Cylinder head bolt removal sequence — 2.0L (4G63) engine

11. Remove the cylinder head and the gasket.

    To install:

12. Thoroughly clean the deck surface of the engine block and the sealing surface of the cylinder head.
13. Measure the length of the cylinder head bolts from below the head to the end, if the bolt measures more than 3.913 in. (99.4mm), replace the bolt.
14. Install a new gasket on the engine block with the identification mark facing upwards.
15. Carefully place the cylinder head on the engine. Apply clean engine oil to the bolts and install the bolts finger-tight.
16. Torque the bolts using the following procedure:
    1. Torque the bolts in sequence to 58 ft. lbs. (78 Nm).
    2. Loosen the bolts completely in the reverse order.
    3. Torque the bolts in sequence to 15 ft. lbs. (20 Nm).
    4. Mark the head bolts and cylinder head as shown.

       Fig. 3: To ensure that the bolts are tightened exactly 180 total degrees, mark the head bolt and cylinder head as shown — 2.0L (4G63) engine

    5. Tighten the bolts in sequence 90 degrees.
    6. Tighten the bolts in sequence an additional 90 degrees.
17. Install or connect the following:
    • Turbocharger to the exhaust manifold, using a new gasket
    • Intake manifold stay
    • Thermostat housing and connect the hoses
    • Heat protector
18. Apply sealant to the semi-circular packing and install it on the cylinder head.
19. Apply sealant at the front of the cylinder head where the camshaft oil seal retainer and the cylinder head come together and install the cylinder head cover using a new gasket.
20. Install or connect the following:
    • Power steering pump
    • Timing belt
    • PCV, breather and vacuum hoses
    • Water hose and the bypass hose
21. Use a new O-ring and connect the lines to the fuel supply rail. Apply a small amount of engine oil to the new O-ring.
22. Install or connect the following:
    • Brake booster vacuum hose
    • Spark plug wires and install the center cover
23. Connect the following connectors:
    • IAC motor
    • Knock sensor
    • HO2S sensor
    • ECT gauge sender
    • ECT sensor
    • Ignition module (power transistor)
    • TP sensor
    • Condenser
    • MAP sensor
    • Injectors
    • Ignition coil
    • CMP sensor
    • CKP sensor
    • air conditioning compressor
    • Engine control wiring harness
24. Install or connect the following:
    • Intake air hose to the throttle body
    • Accelerator cable, adjust
25. Refill the engine with coolant.
26. Connect the negative battery cable.
27. Start the engine and check for leaks.

2.0L (420A) ENGINE

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Relieve the fuel system pressure.
3. Disconnect the negative battery cable.
4. Drain the engine coolant.
5. Remove the air cleaner and air intake duct.
6. Disconnect the following connectors:
   • air conditioning compressor
   • Power steering pressure switch
   • HO2S sensor
   • ECT gauge sender
   • ECT sensor
   • MAP sensor
   • IAT sensor
   • TP sensor
   • IAC motor
   • Injector harness
   • Ignition coil
   • CMP sensor
   • EGR solenoid valve
7. Install or connect the following:
   • Spark plug wires
   • Accelerator cable from the throttle body
   • Heater hoses from the rear of the engine
   • Fuel lines from the fuel supply rail
   • Purge air hose and the brake booster vacuum hose connections
   • Overflow tube connection
   • Upper radiator hose and the water hose connections
   • Timing belt
   • Intake manifold stay
   • Intake and exhaust camshafts
   • Exhaust pipe connection from the exhaust manifold
   • Cylinder head mounting bolts and the cylinder head

   To install:

8. Thoroughly clean the cylinder head and engine block sealing surfaces.
9. Place a new head gasket on the engine block and carefully place the cylinder head on the engine.
10. Coat the threads of the bolts with clean engine oil and install the bolts finger-tight in the engine block.

    NOTE: The short bolts go in the corners.

11. Torque the cylinder head bolts in the following sequence:
    • Torque bolts 1–6 to 25 ft. lbs. (33 Nm), then torque bolts 7–10 to 20 ft. lbs. (27 Nm)
    • Torque bolts 1–6 to 50 ft. lbs. (67 Nm), then torque bolts 7–10 to 20 ft. lbs. (27 Nm)
    • Again, torque bolts 1–6 to 50 ft. lbs. (67 Nm), then torque bolts 7–10 to 20 ft. lbs. (27 Nm)
    • Turn all fasteners 1–10 ¹⁄₄ turn (90 degrees) more in sequence.
12. Use a new gasket and connect the front exhaust pipe to the exhaust manifold.
13. Install or connect the following:
    • Camshafts
    • Timing belt
    • Intake manifold stay
    • Upper radiator hose
    • Water hose to the water pipe
    • Overflow tube
    • Brake booster vacuum hose and purge air hose connection
14. Use a new O-ring and connect the fuel lines to the fuel supply rail.
15. Connect the heater hose.
16. Connect the following connectors:
    • air conditioning compressor
    • Power steering pressure switch
    • HO2S sensor
    • ECT gauge sender
    • ECT sensor
    • MAP sensor
    • IAT sensor
    • TP sensor
    • IAC motor
    • Injector harness
    • Ignition coil
    • CMP sensor
    • EGR solenoid valve
17. Install or connect the following:
    • Spark plug wires
    • Accelerator cable, adjust
    • Air intake duct and the air cleaner assembly
18. Fill the cooling system.

2.4L (4G64) ENGINE

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Relieve the fuel system pressure.
3. Disconnect the negative battery cable.
4. Remove the air cleaner with all air intake hoses.
5. Drain the cooling system.
6. Remove or disconnect the following:
   • Accelerator cable
   • Cable mounting brackets and position the cable aside
   • Breather hose
   • Vacuum lines at the throttle body, label for identification
   • High pressure fuel line, plug
   • Fuel return hose, plug
7. Disconnect the following connectors:
   • air conditioning compressor
   • Power steering pressure switch
   • HO2S sensor
   • ECT gauge sender
   • ECT sensor
   • MAP sensor
   • IAT sensor
   • TP sensor
   • IAC motor
   • Injector harness
   • Ignition coil
   • CMP sensor
   • EGR solenoid valve
8. Remove the spark plug wire cover and wires.
9. At the thermostat case assembly, remove the coolant hoses and unbolt the thermostat case from the engine.
10. Remove the upper timing belt cover.
11. Align all timing marks.
12. Secure the timing belt to the camshaft sprocket with cord or a wire tie.
13. Remove or disconnect the following:
    • Camshaft sprocket
    • Valve cover and the half-round seal
    • Intake manifold stay bracket from the intake manifold
    • Exhaust pipe self-locking nuts and separate the exhaust pipe from the exhaust manifold. Discard the gasket.
14. Loosen the cylinder head mounting bolts in 3 steps, starting from the outside and working inward. Lift off the cylinder head assembly and remove the head gasket.

    To install:

15. Thoroughly clean the mating surfaces of the head and block.
16. Place a new head gasket on the cylinder block with the identification marks at the front top (upward) position. Do not use sealer on the gasket.
17. Inspect the cylinder head bolt length prior to installation. If the length exceeds 3.91 in. (99.4mm), the bolt must be replaced. Install the washer onto the bolt so the chamfer on the washer faces towards the head of the bolt.
18. Carefully install the cylinder head on the block and tighten the cylinder head bolts as follows:
    1. Following the proper tightening sequence, tighten the cylinder head bolts to 58 ft. lbs. (78 Nm).
    2. Loosen all bolts completely.
    3. Torque bolts to 15 ft. lbs. (20 Nm).
    4. Tighten bolts an additional ¹⁄₄ turn.
    5. Tighten bolts an additional ¹⁄₄ turn.
19. Install or connect the following:
    • New exhaust pipe gasket and connect the exhaust pipe to the manifold. Tighten the bolts to 33 ft. lbs. (44 Nm).
    • Thermostat case and tighten the mounting bolts to 18 ft. lbs. (24 Nm)
    • Coolant hoses to the thermostat case
20. Apply sealer to the perimeter of the half-round seal and to the lower edges of the half-round portions of the belt-side of the new gasket. Install the valve cover.
21. Install or connect the following:
    • Camshaft sprocket with the timing belt attached. Remove the cord or wire tie.
    • Upper timing belt cover
    • Intake manifold stay and tighten the mounting bolts to 22 ft. lbs. (30 Nm)
22. Connect the following connectors:
    • air conditioning compressor
    • Power steering pressure switch
    • HO2S sensor
    • ECT gauge sender
    • ECT sensor
    • MAP sensor
    • IAT sensor
    • TP sensor
    • IAC motor
    • Injector harness
    • Ignition coil
    • CMP sensor
    • EGR solenoid valve
23. Install the spark plug wires and cover.
24. Replace the O-rings and connect the fuel lines.
25. Install the air cleaner and intake hose. Connect the breather hose.
26. Fill the cooling system.
27. Connect the negative battery cable

    Fig. 4: Cylinder head bolt removal sequence — 2.4L (4G64) engine

    Fig. 5: Secure the timing belt to the camshaft sprocket and remove the sprocket — 2.4L (4G64) engine

1.5L ENGINE

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Relieve the fuel system pressure. Disconnect the negative battery cable.
3. Drain the cooling system.
4. Remove or disconnect the following:
   • Air intake hose and the air cleaner assembly
   • Ground cable connection and the accelerator cable
   • PCV and the breather hose connection
   • Vacuum hoses from the intake and throttle body, label for reference
   • Vacuum line for the brake booster
   • Upper radiator hose, throttle body hoses, bypass hose and heater hose connections
   • Fuel feed and return lines
   • Spark plug wires
5. Disconnect the electrical harness plugs from the following:
   • CKP and CMP sensors
   • HO2S sensor
   • ECT sensor and gauge sender
   • ISC motor
   • TP sensor
   • IAT
   • EGR temperature sensor
6. Remove or disconnect the following:
   • Electrical harness plugs from the ignition distributor, fuel injectors, power transistor and ground cable
   • Engine control wiring harness
   • Clamp that holds the power steering pressure hose to the engine mounting bracket
7. Place a jack and wood block under the oil pan and carefully lift just enough to take the weight off the engine mounting bracket and remove the bracket.
8. Remove or disconnect the following:
   • Valve cover
   • Timing belt upper cover
9. Rotate the crankshaft clockwise and align the timing marks.
10. Attach the timing belt to the camshaft sprocket with cord or a wire tie.
11. Secure the camshaft from turning and remove the camshaft sprocket with the timing belt attached.
12. Remove the timing belt rear upper cover.
13. Remove the exhaust pipe from the exhaust manifold.
14. Loosen the cylinder head mounting bolts in sequence using 3 steps. Remove the cylinder head.

    Fig. 6: Cylinder head bolt loosening sequence — Mirage with 1.5L (4G15) engine

    To install:

15. Thoroughly clean the mating surfaces of the head and block.
16. Place a new head gasket on the cylinder block with the identification marks facing upward. Do not use sealer on the gasket.
17. Carefully install the cylinder head on the block. Tighten the cylinder head bolts as follows:
    1. 36 ft. lbs. (49 Nm) in the correct sequence
    2. Loosen the bolts completely in the reverse order.
    3. Tighten the bolts in sequence to 14 ft. lbs. (20 Nm)
    4. Tighten each bolt in sequence 90 degrees
    5. Tighten each bolt in sequence an additional 90 degrees
18. Install or connect the following:
    • New exhaust pipe gasket and connect the exhaust pipe to the manifold
    • Upper rear timing cover
19. Align the timing marks and install the cam sprocket. Torque the retaining bolt to 51 ft. lbs. (70 Nm). Check the belt tension and adjust, if necessary. Install the outer timing cover.
20. Install or connect the following:
    • Valve cover and torque the retaining bolts to 16 inch lbs. (1.8 Nm)
    • Engine mount bracket and remove the support jack
    • Clamp that holds the power steering pressure hose to the engine mounting bracket
21. Connect the following:
    • CKP and CMP sensors
    • HO2S sensor
    • ECT sensor and gauge sender
    • ISC motor
    • TP sensor
    • IAT
    • EGR temperature sensor
22. Install or connect the following:
    • Ignition distributor, fuel injectors, power transistor and ground cable
    • Engine control wiring harness
23. Replace the O-rings and connect the fuel lines.
24. Install the air cleaner assembly. Connect the breather hose.
25. Fill the system with coolant.
26. Connect the negative battery cable.

1.8L ENGINE

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Relieve fuel system pressure. Disconnect the negative battery cable.
3. Remove the air cleaner assembly.
4. Drain the cooling system.
5. Disconnect the brake booster vacuum hose and PVC valve connection.
6. Note the locations and disconnect the vacuum hoses from the intake and throttle body.
7. Remove or disconnect the following:
   • Upper radiator hose, overflow tube and the water hose from the thermostat to the throttle body
   • Fuel feed and return lines
   • Accelerator cable connection from the throttle body
   • Oil pressure switch
8. Disconnect the following:
   • HO2S sensor
   • ECT sensor and gauge sender
   • IAC motor
   • EGR temperature sensor
   • TP sensor
   • Knock sensor
   • Fuel injectors
   • Spark plug wires
   • Control harness assembly and position aside
   • Thermostat housing, thermostat and the thermostat case with O-ring from the engine
   • Rocker cover
   • Timing belt upper cover
9. Rotate the crankshaft clockwise and align the timing marks.
10. Attach the timing belt to the camshaft sprocket with cord or a wire tie.
11. Secure the camshaft from turning and remove the camshaft sprocket with the timing belt attached.
12. Remove the timing belt rear upper cover.

    Fig. 7: Cylinder head bolt loosening sequence — 1.8L engine

13. Loosen the cylinder head bolts in 2 or 3 steps in the proper sequence.
14. Remove the cylinder head from the engine.

    CAUTION
    When removing the cylinder head, take care not to bend or damage the plug guide. The plug guide can not be replaced.

    To install:

15. Thoroughly clean the mating surfaces of the head and block.
16. Place a new head gasket on the cylinder block with the identification marks facing upward. Do not use sealer on the gasket.
17. Carefully install the cylinder head on the block.
18. Measure the cylinder head bolts prior to installation. Replace any that exceed 3.795 in. (96.4mm).
19. Apply a small amount of engine oil to the thread section of the bolt and install so the chamfer of the washer faces upward.
20. Tighten the cylinder head bolts as follows:
    1. In the proper tightening sequence, torque bolts to 54 ft. lbs. (75 Nm).
    2. In the reverse order of the tightening sequence, fully loosen all bolts.
    3. In the proper tightening sequence, torque bolts to 14 ft. lbs. (20 Nm).
    4. In the proper tightening sequence, tighten bolts ¹⁄₄ turn (90 degrees).
    5. In the proper tightening sequence, tighten bolts an additional ¹⁄₄ turn (90 degrees).
21. Install the camshaft sprocket and tighten the bolt to 65 ft. lbs. (90 Nm), while holding the sprocket in place using the appropriate wrench. Confirm proper timing mark alignment.
22. Install the upper timing belt cover and rocker cover. Torque the rocker cover bolts to 29 inch lbs. (3.3 Nm).
23. Loosen the water pipe mounting bolt for ease of thermostat housing installation.
24. Apply a thin bead of RTV sealant to the water tube connection on the thermostat case.
25. Apply a small amount of water to the O-ring of the water inlet pipe and press the thermostat case assembly onto the water inlet pipe. Install the thermostat case assembly mounting bolt tightening to 16 ft. lbs. (22 Nm).
26. Tighten the water pipe mounting bolt.
27. Install the thermostat into the housing so the jiggle valve is located at the top. Tighten the housing bolts to 10 ft. lbs. (14 Nm).
28. Connect the following:
    • HO2S sensor
    • ECT sensor and gauge sender
    • IAC motor
    • EGR temperature sensor
    • TP sensor
    • Knock sensor
    • Fuel injectors
29. Install or connect the following:
    • Upper radiator hose to the thermostat housing
    • Accelerator cable connection to the throttle body
    • Oil pressure switch
    • Spark plug wires
    • Control harness assembly
30. Replace the O-ring for the high pressure hose and install a new clamp on the return hose and reconnect the fuel lines.
31. Install or connect the following:
    • Air intake hose
    • Breather hose and air cleaner case cover
    • Brake booster and the PCV vacuum hoses
32. Fill the system with coolant.
33. Connect the negative battery cable