Cylinder Head Installation
Cylinder Head InstallationInstall the cylinder head in the reverse order of removal:
1. Clean the cylinder head and block surface.
2. Install the new cylinder head gasket (A) and dowel pins (B) on the engine block. Always use a new cylinder head gasket.
3. Check that the crankshaft keyway is facing up.
4. Install the cylinder head on the engine block.
5. Measure the diameter of each cylinder head bolt at point A and point B.
6. If either diameter is less than 8.6 mm (0.34 in.), replace the cylinder head bolt.
7. Apply new engine oil to the threads and flange of all cylinder head bolts.
8. Tighten the cylinder head bolts in sequence to 29 Nm (3.0 kgf-m, 22 lbf-ft). 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 from the first step.
9. Tighten all cylinder head bolts an additional 130°.
NOTE: Remove the cylinder head bolt if you tightened it beyond the specified angle, and go back to step 5 of the procedure.
10. Install the cam chain guide mounting bolt.
11. Install the cam chain to the camshaft sprocket by aligning the reference mark (A), then install the camshaft sprocket on the camshaft.
12. Hold the camshaft with a 27 mm open-end wrench, then tighten the bolt.
13. Loosely install the crankshaft pulley.
14. Apply new engine oil to the slider surface of the cam chain tensioner slider through the oil return hole in the cylinder head.
15. Hold the crankshaft pulley and set the socket wrench (A) on the camshaft sprocket bolt.
16. Turn the camshaft clockwise to compress the cam chain tensioner, then remove the 6 x 1.0 mm bolt (B).
NOTE:
^ Turning torque should not exceed 56 Nm (5.7 kgf-m, 41 lbf-ft), when turning the camshaft.
^ Do not turn the camshaft counterclockwise.
17. Check the chain case oil seal for damage. If the oil seal is damaged, replace the chain case oil seal.
18. Remove old liquid gasket from the chain case mating surfaces, bolts, and bolt holes.
19. Clean and dry the chain case mating surfaces.
20. Apply liquid gasket, P/N 08717-0004, 08718-0001, 08718-0003, or 08718-0009, to the cylinder head and engine block mating surface of the chain case. Install the component within 5 minutes of applying the liquid gasket.
NOTE:
^ Apply a 1.5 mm wide bead of the liquid gasket along the broken line (A).
^ Apply a 3.0 mm wide bead of the liquid gasket to the engine block upper surface contact areas (B) on the chain case.
^ If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.
^ If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.
21. Apply liquid gasket, P/N 08718-0001 or 08718-0009, to the oil pan mating surface of the chain case. Install the component within 5 minutes of applying the liquid gasket.
NOTE:
^ Apply a 1.5 mm wide bead of the liquid gasket along the broken line (A).
^ Apply a 5.0 mm wide bead of the liquid gasket to the shaded area (B).
^ If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.
^ If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.
22. Set the edge of the chain case (A) to the edge of the oil pan (B), then install the chain case on the engine block (C).
NOTE:
^ When installing the chain case, do not slide the bottom surface onto the oil pan mounting surface.
^ Wait at least 30 minutes to allow the liquid gasket to cure before filling the engine with oil.
^ Do not run the engine for at least 3 hours after installing the chain case.
23. Install the harness clamps, and connect the crankshaft position (CKP) sensor connector.
24. Install the side engine mount/bracket assembly, then install the ground cable.
25. Install the crankshaft pulley.
26. Install the cylinder head cover.
27. Install the water pump pulley.
28. With A/C: Install the idler pulley.
29. Install the alternator bracket mounting bolts.
30. Install the drive belt and adjust it.
31. Install the connecting pipe (A), using a new O-ring (B).
32. Install the water bypass hose (C).
33. Install the harness holder (A), ground cable (B), harness clamps (C), water bypass hose (D) and engine junction connector clamp (E).
34. Install the fuel rail.
35. Install the exhaust manifold.
36. Install the intake manifold.
37. Install the heater hoses.
38. Install the upper radiator hose (A) and the lower radiator hose (B).
39. Install the purge hose (A), water bypass hoses (B), throttle body connector (C) and evaporative emission (EVAP) canister purge valve connector (D).
40. Install the air cleaner assembly.
41. Adjust the valve clearance.
42. After installation, check that all tubes, hoses and connectors are installed correctly.
^ Rocker arm oil control solenoid connector
^ Rocker arm oil pressure switch connector
^ Exhaust gas recirculation (EGR) valve/EGR valve position sensor connector
^ Four injector connectors
^ Engine coolant temperature (ETC) sensor 1 connector
^ Camshaft position (CMP) sensor connector
43. Inspect for fuel leaks. Turn the ignition switch 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.
44. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open.
45. Do the crankshaft position (CKP) pattern clear/CKP pattern learn procedure.
46. Inspect the idle speed.
47. Inspect the ignition timing.