Cylinder Head Installation

Cylinder Head Installation

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

2. Install a cooling control spacer (A) in the engine block whenever the engine block is replaced, and check for free play between the cooling spacer and the engine block. If there is any free play, install a new cooling control spacer.

NOTE:

- Make sure the cooling control spacer contacts the bottom of the water jacket (B).
- The clearance between the top part of the cooling control spacer (C) and the top edge of the cylinder block (D) must be more than 0.2mm.





3. Install the new cylinder head gasket (E) and the dowel pins (F) 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 flange of all cylinder head bolts.

8. Torque the cylinder head bolts in sequence to 29 N-m (3.0 kgf-m, 22 lbf-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.






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





10. Install the cam chain Cam Chain Installation.

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

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

13. Install the water pump Service and Repair.

14. Install the drive belt Service and Repair.

15. Connect the upper radiator hose (A), the water bypass hose (B), and the heater hose (C).






16. Install the harness holder (A) and the ground cable (B).






17. Install the fuel pipe nut (A) and the fuel pipe clamp (B).






18. Connect the breather hose, and install the harness holder.

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

- Four injector connectors
- ECT sensor 1 connector
- CMP sensor connector
- Secondary HO2S connector
- Rocker arm oil control solenoid connector

20. Install the eight ignition coils Service and Repair.

21. Install the intake manifold.

22. Install the air cleaner Service and Repair.

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

24. Do the 12 volt battery installation procedure Removal and Replacement.

25. 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.

26. Refill the radiator with engine coolant, and bleed the air from the cooling system.

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

28. Inspect the idle speed Testing and Inspection.

29. Inspect the ignition timing Testing and Inspection.