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 (B) and the dowel pins (C) 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 to TDC. The "UP" mark (A) on the camshaft sprocket should be at the top, and the TDC grooves (B) on the camshaft sprocket should line up with the top edge of the head.

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 (0.42 in.), replace the cylinder head bolt.

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






10. Tighten the cylinder head bolts in sequence to 39 N-m (4.0 kgf-m, 29 lbf-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.






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 60 °.
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 cam chain. Cam Chain Installation

13. Adjust the valve clearance. Adjustments

14. Install the cylinder head cover. Cylinder Head Cover Installation

15. Install the thermostat housing. Service and Repair

16. Install the three way catalytic converter (TWC). Service and Repair

17. Connect the following engine wire harness connectors, and install the wire harness clamps to the cylinder head:
- Four fuel injector connectors

- Engine coolant temperature (ECT) sensor 1 connector

- Air fuel ratio (A/F) sensor connector

- Secondary heated oxygen sensor (secondary HO2S) connector

- Exhaust gas recirculation (EGR) valve connector

- Rocker arm oil control valve connector

- Rocker arm oil pressure sensor (EOP sensor) connector

- EVAP canister purge valve connector

- Camshaft position (CMP) sensor connector





18. M/T model: Connect the upper radiator hose (A) and the heater hose (B).






19. A/T model: Connect the upper radiator hose (A), the heater hose (B), and the water bypass hose (C).






20. Install the harness holder (A) on the cylinder head, then install the air cleaner bracket (B).






21. Install the harness clamps (A), and connect the positive crankcase ventilation (PCV) hose to the clamp (B).

22. Install the intake manifold. Service and Repair

23. Install the drive belt. Drive Belt Removal/Installation

24. Install the air cleaner assembly. Service and Repair

25. Do the battery terminal reconnection procedure. Procedures

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

27. Inspect for fuel leaks. Turn the ignition switch to ON (II) (do not operate the starter) so that 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.

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

29. Do the engine control module (ECM)/powertrain control module (PCM) idle lean procedure. ECM/PCM Idle Learn Procedure (A/T)

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

31. Inspect the idle speed. Testing and Inspection

32. Inspect the ignition timing. Testing and Inspection