Cylinder Head Installation

Cylinder Head Installation





1. Measure the diameter of each cylinder head bolt at point A and point B. If either diameter is less than 11.5 mm (0.45 inch), replace the cylinder head bolt.
2. Clean the cylinder head and engine block surfaces.





3. Apply liquid gasket, P/N 08717-0004, 08718-0001, 08718-0003, or 08718-0009, to the shaded areas (A) of the cylinder head gasket mating surface of the block and chain case.





4. Install the dowel pins (A) and the new cylinder head gasket (B).





5. Apply liquid gasket, P/N 08717-0004, 08718-0001, 08718-0003, or 08718-0009, to the cylinder head mating surface of the block and chain case within 5 mm of the edge of the cylinder head gasket.
6. Install the cylinder head on the engine block.
7. Apply new engine oil to the threads and under the heads of all the cylinder head bolts.





8. Tighten the cylinder head bolts in sequence to 29 Nm (3.0 kgf-m, 22 ft. lbs.) Use a beam-type torque wrench. When using a preset-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.
9. Tighten all cylinder head bolts in two steps (90° per step). If you are using a new cylinder head bolt, tighten the bolt an extra 90°.
10. Tighten the 8 mm bolts (A) to 22 Nm (2.2 kgf-m, 161 ft. lbs.).





11. Make sure the crankshaft pulley is at Top Dead Center (TDC). Align the TDC mark (A) on the crankshaft pulley with the pointer (B) on the chain case.





12. Assemble the idler gear (A) and cam chain sprocket (B) with three mounting bolts(C). Torque the bolts to 13 Nm (1.3 kgf-m, 9.4 ft. lbs.).
13. Place the assembly into the cylinder head.
14. Install the cam chain on the sprocket, then fit the assembly into the cylinder head.





15. Turn the idler gear counterclockwise to relieve cam chain free play, and check the alignment of the TDC marks (A) on the cam chain sprocket with the cylinder head surface. If the cam chain sprocket is not positioned at TDC, remove the idler gear from the cylinder head and reposition the cam chain to bring the cam chain sprocket to TDC.





16. Apply new engine oil to the idler gear/cam chain sprocket center bolt threads (A). Install a new O-ring (B) on the bolt.
17. Install the washer (C) on the idler gear, and tighten the center bolt.
18. Clamp the cam chain auto-tensioner in a soft-jawed vise.





19. Turn the 5 x 0.8 mm bolt (A) clockwise to compress the bottom of the auto-tensioner, then insert the set pin (B), P/N 14811-PCX-005.





20. Remove the 5 x 0.8 mm bolt from the maintenance hole. Install a new O-ring (A), then install the nozzle (B) and end cover (C).





21. Install the cam chain auto-tensioner (A) in the cylinder head with new O-rings (B).
22. Remove the maintenance bolt (C) from the cylinder head.





23. Remove the set pin (A) from the cam chain autotensioner. Reinstall the maintenance bolt (B) with a new washer (C).





24. Install the rocker arm assembly, and check the alignment of the TDC marks (A) on the cam chain sprocket with the cylinder head surface.
25. Align the TDC marks (B) on the intake camshaft gear (C) and the exhaust camshaft gear (D), and install the camshafts.
26. Apply new engine oil to the bolt threads of all the camshaft holder bolts.





27. Put the camshaft holders on the cylinder head, then tighten all bolts to 22 Nm (2.2 kgf-m, 16 ft. lbs.).





28. Make sure the camshaft gears are at TDC.
29. Adjust the valve clearance.
30. Install the cylinder head cover.





31. Install the exhaust manifold (A) using new gaskets (B) and new self-locking nuts.
32. Install the exhaust manifold bracket (D). Make sure the smooth sides of the washers (E) face the exhaust manifold bracket.
33. Put the exhaust manifold cover on the exhaust manifold.





34. Install the heat shield.





35. Tighten the four bolts securing the exhaust manifold cover.





36. Install the intake manifold (A) with a new gasket (B).
37. Install the injectors.





38. Install the water bypass hose (A), and tighten the two bolts (B) securing the intake manifold bracket.





39. Install the water outlet cover (A) with a new O-ring (B).





40. Install the air hose (A), and tighten the bolt (B) securing the intake manifold bracket.





41. Install the Evaporative Emission (EVAP) canister hose.





42. Install the brake booster vacuum hose (A), fuel return hose (B), and fuel feed hose (C), using new washers (D).
43. Install the drive belt.





44. Install the air cleaner housing/intake air duct assembly (A), then install the vacuum hoses (B). Connect the air control solenoid valve connector (C).
45. Install the throttle cable, then adjust the cable.
46. After installation, check that all tubes, hoses, and connectors are installed correctly.
47. After assembly, wait at least 30 minutes before filling the engine with oil.
48. Clean the battery posts and cable terminals with sandpaper, then assemble them and apply grease to prevent corrosion.
49. Inspect for fuel leaks. Turn the ignition switch ON (II) (do not operate the starter) so that the fuel pump runs for about 2 seconds and pressurizes the fuel. Repeat this operation on two or three times then check for fuel leakage at any point in the fuel line.
50. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open.
51. Perform the Engine Control Module (ECM) idle learn procedure.
52. Inspect the idle speed.
53. Inspect the ignition timing.
54. Enter the anti-theft code for the radio, then enter the customer's radio station presets.
55. Set the clock.