Cylinder Head Installation
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 cylinder block. Always use a new cylinder head gasket.
3. Check that the crankshaft keyway is facing up.
4. Install the cylinder head on the block.
5. Apply engine oil to the threads and under the bolt heads of all cylinder head bolts.
6. Tighten the cylinder head bolts in sequence to 29 Nm (3.0 kgf-cm, 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 from the first step.
7. Tighten all cylinder head bolts an additional 130°
8. Install the cam chain guide mounting bolt.
9. Install the cam chain around the camshaft sprocket aligned with the reference mark (A), then install the camshaft sprocket on the camshaft.
10. Hold the camshaft with an open-end wrench, then tighten the bolt.
11. Loosely install the crankshaft pulley.
12. Apply engine oil to the sliding surface of the cam chain tensioner through the oil return hole in the cylinder head.
13. Hold the crankshaft pulley and set the socket wrench (A) on the camshaft sprocket bolt.
14. Turn the camshaft clockwise to compress the cam chain tensioner rail, then remove the 6 x 1.0 mm bolt (B)
NOTE:
^ Turning torque should not exceed 44 Nm (4.5 kgf-cm, 33 ft. lbs.), when turning the camshaft.
^ Do not turn the camshaft counterclockwise.
15. Check the chain case oil seal for damage. If the oil seal is damaged, replace the chains case oil seal.
16. Remove old liquid gasket from the chain case mating surfaces, bolts, and bolt holes.
17. Clean and dry the chain case mating surfaces.
18. Apply liquid gasket, P/N 08718-0009, to the cylinder block mating surface of the chain case and the inner threads of the holes.
NOTE:
^ Apply a 1.5 mm wide bead of liquid gasket along the broken line (A).
^ Apply a 3.0 mm wide bead of liquid gasket to the cylinder block upper surface contact areas (B) on the chain case.
19. Apply liquid gasket, P/N 08718-0009 to the oil pan mating surface of the chain case and the inner threads of the holes.
NOTE:
^ Apply a 1.5 mm wide bead of liquid gasket along the broken line (A).
^ Apply a 5.0 mm wide bead of liquid gasket to the shaded area (B).
^ Do not install the parts if 5 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing old residue.
20. Set the edge of the chain case (A) to the edge of the oil pan (B), then install the chain case on the cylinder block (C).
NOTE: When installing the chain case, do not slide the bottom surface on the oil pan mounting surface.
21. Install the dipstick tube (A), using a new O-ring (B).
22. Install the upper bracket, then tighten the mounting nuts in the numbered sequence shown.
23. Install the ground cable.
24. Install the crankshaft pulley.
25. Install the cylinder head cover.
26. Install the water pump pulley.
27. Install the drive belt and adjust it.
28. Install the connecting pipe (A), using a new O-ring (B).
29. Install the harness holder (C) to the brackets.
30. Install the evaporative emission (EVAP) canister hose (A) and brake booster vacuum hose (B).
31. Install the lower radiator hose joint (A), use new O-ring (B).
32. Install the upper radiator hose (C) and heater hoses (D).
33. Install the exhaust manifold.
34. Install the intake manifold.
35. Install the fuel feed hose.
36. Install the air cleaner housing.
37. After installation, check that all tubes, hoses and connectors are installed correctly.
38. 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 two or three times, then check for fuel leakage at any point in the fuel line.
39. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open.
40. Inspect the idle speed.
41. Inspect the ignition timing.