Cylinder Head Installation

Cylinder Head Installation

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

2. Clean the cylinder head and block surface.






3. Install the new cylinder head gasket (A) and 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. Install the cylinder head on the block.






6. Measure the diameter of each cylinder head bolt at point A and point B.

7. If either diameter is less than 10.6 mm (0.42 in.), replace the cylinder head bolt.

8. Apply engine oil to the threads and under the bolt heads of all cylinder head bolts.






9. 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-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.






10. After torquing, tighten all cylinder head bolts in two steps (90 ° per step) using the sequence shown in step 9. 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.

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

12. Install the cam chain. Cam Chain Installation






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






14. Install the harness clamps (A), then install the two bolts (B) securing the evaporative emission (EVAP) canister purge control valve mounting bracket.






15. Install the EVAP canister hose (A), the brake booster vacuum hose (B), and the vacuum hose (C).






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

17. Connect the engine wire harness connectors and wire harness clamps to the cylinder head.
- Engine coolant temperature (ECT) sensor 1 connector

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

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

- EVAP canister purge valve connector

18. Install the exhaust manifold and turbocharger. Service and Repair

19. Install the intake manifold. Service and Repair

20. Install the drive belt. Service and Repair

21. Install the air cleaner housing. Service and Repair

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

23. 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.

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

25. Inspect the idle speed. Testing and Inspection

26. Inspect the ignition timing. Testing and Inspection