Cylinder Head Installation

Cylinder Head Installation

1. Clean the cylinder head and the engine block surface.

2. Install a new coolant separator (A) in the engine block whenever the engine block is replaced.






3. Install the new cylinder head gasket (A) and the dowel pins (B) on the engine block. Always use a new cylinder head gasket.






4. Set the crankshaft to top dead center (TDC). Align the TDC mark (A) on the crankshaft sprocket with the pointer (B) on the engine block.





5. Install the cylinder head on the engine block.

6. Measure the diameter of each cylinder head bolt at point A and point B.





7. If either diameter is less than 10.6 mm (0.42 in), replace the cylinder head bolt.

8. Apply new engine oil to the threads and under the bolt heads of all cylinder head bolts.

9. Tighten the cylinder head bolts in sequence to 39 Nm (4.0 kg-m, 29 lb-ft). Use a beam-type torque wrench. When using a preset click-type torque wrench, be sure to tighten slowly and do not overtighten. If a bolt makes any noise while you are torquing it, loosen the bolt and retighten it from the first step.






10. After torquing, tighten all cylinder head bolts in two steps (90 ° per step) using the sequence shown in step 9 Cylinder Head Installation. If you are using a new cylinder head bolt, tighten the bolt an extra 90 °.

NOTE: Remove the cylinder head bolt if you tightened it beyond the specified angle, and go back to step 6 Cylinder Head Installation of the procedure. Do not loosen it back to the specified angle.






11. Install the rocker arm assembly Rocker Arm Assembly Installation.

12. Install the cam chain Cam Chain Installation.

13. Connect the following engine wire harness connectors, and install the wire harness clamps to the cylinder head:

- Engine coolant temperature (ECT) sensor 1 connector
- Camshaft position (CMP) sensor A (Intake) connector
- Camshaft position (CMP) sensor B (Exhaust) connector
- Rocker arm oil control solenoid connector
- Rocker arm oil pressure switch connector
- Evaporative emission (EVAP) canister purge valve connector
- Variable valve timing control (VTC) oil control solenoid valve connector
- Engine oil pressure switch connector

14. Install the two bolts (A) securing the connecting pipe.





15. Connect the water bypass hose (B).

16. Connect the upper radiator hose (A), the heater hoses (B), and the water bypass hose (C).






17. Install the four bolts securing the EVAP canister purge valve bracket.






18. Connect the four fuel injector connectors (A), install the ground cables (B).






19. Connect the fuel feed hose (A) Fuel Line/Quick-Connect Fitting Installation, then install the quick-connect fitting cover (B).






20. Connect the EVAP canister hose (A).






21. Install the warm up TWC Warm Up TWC Removal/Installation.

22. Install the intake manifold Service and Repair.

23. Install the drive belt Service and Repair.

24. After installation, check that all tubes, hoses, and connectors are installed correctly.

25. Inspect for fuel leaks. Turn the ignition switch to ON (II) (do not operate the starter ) so the fuel pump runs for about 2 seconds and pressurizes the fuel line. Repeat this operation three times, then check for fuel leakage at any point in the fuel line.

26. Refill the radiator with engine coolant, and bleed the air from the cooling system Service and Repair.

27. Check for fluid leaks.

28. Do the powertrain control module (PCM) idle learn procedure PCM Idle Learn Procedure.

29. Do the crankshaft position (CKP) pattern clear/CKP pattern learn procedure Initial Inspection and Diagnostic Overview.

30. Inspect the idle speed Testing and Inspection.

31. Inspect the ignition timing Testing and Inspection.