Cylinder Head Installation

Cylinder Head Installation

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





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

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. Set the camshaft pulley to TDC.

6. Install the cylinder head on the engine block.

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





8. If either diameter is less than 10.6 mm (0.417 in), replace the cylinder head bolt.

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

10. Torque the cylinder head bolts in sequence to 39 Nm (4.0 kg-m, 29 lb-ft) with a beam-type torque wrench if possible. 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 tighten it from the first step.






11. After torquing, tighten all cylinder head bolts in two steps (90 ° per step) using the sequence shown in step 10. 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 7 of the procedure. Do not loosen it back to the specified angle.






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

13. Install the cam chain Cam Chain Installation.

14. Tighten the three bolts (A) securing the EVAP canister purge valve bracket, and tighten the two bolts (B) securing the harness brackets.





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

- Four injector connectors
- ECT sensor 1 connector
- CMP sensor A connector (Intake side)
- CMP sensor B connector (Exhaust side)
- EVAP canister purge valve connector
- Rocker arm oil control solenoid connector
- Rocker arm oil pressure switch connector

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






17. Connect the PCV hose (A), and install the ground cable (B).





18. Install the exhaust manifold Service and Repair.

19. Install the intake manifold Service and Repair.

20. Connect the EVAP canister hose (A) and the brake booster vacuum hose (B).






21. Tighten the bolt securing the connecting pipe support bracket to the engine block.






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






23. Install the intake air duct (A), then connect the MAF sensor/IAT sensor connector (B), the vacuum hose (C) and the breather pipe (D).






24. Install the drive belt Service and Repair.

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

26. 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.

27. Refill the radiator with engine coolant, and bleed the air from the cooling system with the heater valve open Service and Repair.

28. Do the ECM/PCM idle lean procedure ECM/PCM Idle Learn Procedure.

29. Do the CKP pattern clear/CKP pattern learn procedure.

30. Inspect the idle speed Testing and Inspection.

31. Inspect the ignition timing Testing and Inspection.