Diesel Data: Automotive Repair

Cylinder Head Installation




Cylinder Head Installation

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

2. Clean and install the oil control orifices (A) with new O-rings (B).





3. Install the dowel pins (C) and the new cylinder head gaskets (D).

4. Clean the timing belt pulleys, the timing belt guide plate, and the upper and lower covers.

5. Set the timing belt drive pulley to top dead center (TDC) by aligning the TDC mark (A) on the tooth of the timing belt drive pulley with the pointer (B) on the oil pump.






6. Set the camshaft pulleys to TDC by aligning the TDC marks (A) on the camshaft pulleys with the pointers (B) on the back covers.

FRONT





REAR





7. Install the cylinder heads on the engine block.

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





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

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

11. Torque the cylinder head bolts in sequence to 29 Nm (3.0 kg-m, 22 lb-ft) using 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.

Front





Rear





12. After torquing, tighten all cylinder head bolts in two steps (90 ° per step) using the sequence shown in step 11. 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 8 of the procedure. Do not loosen it back to the specified angle.






13. Install the timing belt Timing Belt Installation.

14. Adjust the valve clearance Adjustments.

15. Install the cylinder head covers Cylinder Head Cover Installation.

16. Install the water passage Water Passage Replacement.

17. Install the injector bases Injector Base Removal/Installation.

18. Install the connector bracket (A) to the front cylinder head.






19. Install the harness clamp bracket (A) to the rear cylinder head.






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






21. Install the front warm up three way catalytic converter (front WU-TWC) and the rear warm up three way catalytic converter (rear WU-TWC).

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

- Six injector connectors
- Engine coolant temperature (ECT) sensor 1 connector
- Front rocker arm oil pressure switch connector
- Rear rocker arm oil pressure switch connector
- Camshaft position (CMP) sensor connector
- Front air fuel ratio (A/F) sensor 1 connector
- Rear air fuel ratio (A/F) sensor 1 connector
- Front secondary heated oxygen sensor 2 (secondary HO2S) connector
- Rear secondary heated oxygen sensor 2 (secondary HO2S) connector
- Rocker arm oil control solenoid A (BANK 1) connector
- Rocker arm oil control solenoid A (BANK 2) connector
- Rocker arm oil control solenoid B (BANK 1) connector
- Knock sensor connector

23. Install the six ignition coils Service and Repair.

24. Install the intake manifold Intake Manifold Removal/Installation.

25. Install the alternator Removal and Replacement.

26. Install the power steering (P/S) pump (A) and tighten the bolt (B) securing the P/S hose bracket (C).






27. Install the drive belt Service and Repair.

28. Do the battery installation procedure Removal and Replacement.

29. Install the air intake duct.

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

31. 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.

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

33. Check for fluid leaks.

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

35. Do the crankshaft position (CKP) pattern clear/CKP pattern learn procedure.

36. Inspect the idle speed Testing and Inspection.

37. Inspect the ignition timing Testing and Inspection.