Cylinder Head Installation

Cylinder Head Installation

NOTE: Keep the cam chain away from magnetic fields.

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

2. Install the new cylinder head gasket (A) and the dowel pins (B) on the engine block. Always use a new cylinder head gasket.





3. Set the crankshaft to top dead center (TDC). Align the TDC mark on the crankshaft sprocket with the pointer on the oil pump.

4. Set the No. 1 piston at TDC. The "UP" mark on the camshaft sprocket should be at the top, and the TDC grooves on the camshaft sprocket should line up with the top edge of the head.

5. Install the cylinder head on the engine block.

6. Apply new engine oil to the threads and flange of all cylinder head bolts. Be sure to install the 165 mm long head bolt (A) in the location shown.





7. Torque the cylinder head bolts in sequence to 29 Nm (3.0 kg-m, 22 lb-ft) with a beam-type torque wrench if possible. 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.

8. Tighten all cylinder head bolts an additional 130 °.

NOTE: Remove the cylinder head bolt if you tightened it beyond the specified angle.






9. Install the cam chain guide mounting top bolt.






10. Install the cam chain around the camshaft sprocket aligned with the reference mark (A), then install the camshaft sprocket on the camshaft.






11. Apply new engine oil to the bolt threads and flange. Hold the camshaft with a 27 mm open-end wrench, then tighten the bolt.









12. Loosely install the crankshaft pulley.

13. Apply new engine oil to the sliding surface of the cam chain tensioner through the oil return hole in the cylinder head.






14. Hold the crankshaft pulley and set the socket wrench (A) on the camshaft sprocket bolt.





15. 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 44 Nm (4.5 kg-m, 33 lb-ft), when turning the camshaft.
- Do not turn the camshaft counterclockwise.

16. Check the chain case oil seal for damage. If the oil seal is damaged, replace the chain case oil seal Service and Repair.

17. Remove all of the old liquid gasket from the chain case mating surfaces, the bolts, and the bolt holes.

18. Clean and dry the chain case mating surfaces.

19. Apply liquid gasket, P/N 08717-0004, 08718-0003, or 08718-0009 to the cylinder head and engine block mating surface of the chain case and the inside edge of the threaded bolt holes. Install the component within 5 minutes of applying the liquid gasket.

NOTE:

- Apply a 1.5 mm (0.059 in) diameter bead of liquid gasket along the broken lines.
- Apply a 3.0 mm (0.118 in) diameter bead of liquid gasket to the engine block upper surface mating areas 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.

20. Apply liquid gasket, P/N 08717-0004, or 08718-0009 to the oil pan mating surface of the chain case and the inside edge of the threaded bolt holes. Install the component within 5 minutes of applying the liquid gasket.

NOTE:

- Apply a 1.5 mm (0.059 in) diameter bead of liquid gasket along the broken lines (A).
- Apply a 5.0 mm (0.197 in) diameter bead of 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.





21. 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). Wipe off the excess liquid gasket on the oil pan and chain case mating area.

NOTE:

- When installing the chain case, do not slide the bottom surface on the oil pan mounting surface.
- Wait at least 30 minutes before filling the engine with oil.
- Do not run the engine for at least 3 hours after installing the chain case.










22. Install the dipstick tube (A) with a new O-ring (B). Connect the CKP sensor connector (C) and the harness clamps (D).





23. Install the side engine mount bracket, then loosely install the mount mounting bolts and nut shown.

24. Install the ground cable.

25. Loosen the transmission mount bracket support bolt and nuts.

26. Loosen the lower torque rod mounting bolts.

27. Remove the jack and the wood block.

28. Tighten the side engine mount bracket mounting bolts and nut in the numbered sequence shown.

29. Tighten the transmission mount bracket support bolt and nuts.

30. Tighten the lower torque rod mounting bolts in the numbered sequence shown.

31. Install the crankshaft pulley.

32. Install the warm-up TWC Warm Up TWC Removal/Installation.

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

34. Install the water pump Testing and Inspection.

35. Install the drive belt Service and Repair.

36. Connect the upper radiator hose (A), the lower radiator hose (B), the water bypass hose (C), and the heater hoses (D).





37. Install the EVAP canister purge valve bracket bolts and the fuel pipe nut, then connect the purge joint to the bracket.

38. Install the harness clamp, then connect the EVAP canister purge valve connector.

39. Connect the breather hose and install the harness holder..

40. Install the eight ignition coils Service and Repair.

41. Install the harness clamp (A), then CMP sensor (B) and the ECT sensor 1 connector (C).






42. Install the connecting pipe (A) with a new O-ring (B) and install the harness clamp (C), then connect the knock sensor connector (D).






43. Install the intake manifold.

44. Install the air cleaner Service and Repair.

45. Install the engine cover.

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

47. 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.

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

49. Check for fluid leaks.

50. Do the CKP pattern clear/CKP pattern learn procedure.

51. Inspect the idle speed Testing and Inspection.

52. Inspect the ignition timing Testing and Inspection.