Cylinder Head Installation

Cylinder Head Installation

1. Clean the cylinder head and the 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 oil pump.






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

8. Tighten 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-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 °.





10. Install the cam chain Cam Chain Installation.

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

12. Install the harness holder (A), then install the ground cable (B).






13. Install the harness holder.





14. Connect the engine wire harness connectors, and install the wire harness clamps to the cylinder head.

- Four injector connectors
- Engine coolant temperature (ECT) sensor 1 connector
- Camshaft position (CMP) sensor connector
- Secondary heated oxygen sensor (secondary HO2S) connector
- Rocker arm oil control solenoid connector

15. Install the warm up three way catalytic converter (WU-TWC) Warm Up TWC Removal/Installation.

16. Install the intake manifold/chamber assembly Intake Manifold/Chamber Assembly Removal/Installation.

17. Install the upper radiator hose (A), the heater hose (B), and the water bypass hose (C).





18. Install the heater hose to the clamps (D).

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





20. Install the air cleaner housing assembly Service and Repair.

21. Do the battery installation procedure Removal and Replacement.

22. 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.

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

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

25. Inspect the idle speed Testing and Inspection.

26. Inspect the ignition timing Testing and Inspection.