Cylinder Head Installation

Cylinder Head Installation

1. Install a new coolant separator (A) in the engine block whenever the engine block is replaced.

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






3. Install the new cylinder head gasket (A) and the dowel pins (B) 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 pulley to TDC. Cam Chain Installation

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 90 °.
NOTE: Remove the cylinder head bolt if you tightened it beyond the specified angle, and go back to step 6 of the procedure. Do not loosen it back to the specified angle.

12. Install the rocker arm assembly. Rocker Arm Assembly Installation

13. Install the cam chain. Cam Chain Installation

14. 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

- Camshaft position (CMP) sensor A (Intake) connector

- Camshaft position (CMP) sensor B (Exhaust) connector

- Rocker arm oil control valve connector

- Rocker arm oil pressure switch connector

- EVAP canister purge valve connector

- Variable valve timing control (VTC) oil control solenoid valve connector

- Engine oil pressure switch connector





15. Install the bolt securing the connecting pipe.






16. Connect the upper radiator hose (A) and the heater hoses (B).






17. Install the harness holder bracket (A), then install the harness holder (B).






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






19. Connect the evaporative emission (EVAP) canister hose (A) and the brake booster vacuum hose (B).

20. Install the exhaust manifold. Service and Repair

21. Install the intake manifold. Service and Repair

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

23. Install the air cleaner assembly. Service and Repair

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

25. 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.

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

27. Do the engine control module (ECM) idle learn procedure. ECM Idle Learn Procedure

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

29. Inspect the idle speed. Testing and Inspection

30. Inspect the ignition timing. Testing and Inspection