Cylinder Head Installation
Cylinder Head Installation
1. Clean the cylinder head and engine block surface.
2. Clean and install the oil control orifices (A). Always use new O-rings (B).
3. Install the dowel pins (C) and new cylinder head gaskets (D).
4. Clean the timing belt pulleys, timing belt guide plate, and the upper and lower covers.
5. Set the timing belt drive pulley to top dead center (TDC) by aligning the TDC mark (A) on the tooth of the timing belt drive pulley with the pointer (B) on the oil pump.
6. Set the camshaft pulleys to TDC by aligning the TDC marks (A) on the camshaft pulleys with the pointers (B) on the back covers.
FRONT
REAR
7. Install the cylinder heads on the engine block.
8. Measure the diameter of each cylinder head bolt at point A and point B.
9. If either diameter is less than 11.3 mm (0.44 in), replace the cylinder head bolt.
10. Apply new engine oil to the threads and under the bolt heads of all cylinder head bolts.
11. Torque the cylinder head bolts in sequence to 30 Nm (3.0 kg-m, 22 lb-ft) with use 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.
FRONT
REAR
12. After torquing, tighten all cylinder head bolts in two steps (90 ° per step) using the sequence shown in step 11. 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 8 of the procedure. Do not loosen it back to the specified angle.
13. Install the timing belt Timing Belt Installation.
14. Adjust the valve clearance Adjustments.
15. Install the cylinder head covers Cylinder Head Cover Installation.
16. Install the water passage Water Passage Replacement.
17. Install the injector bases Injector Base Removal/Installation.
18. Install the connector bracket to the front cylinder head.
19. Install the engine mount control solenoid valve bracket to the rear cylinder head.
20. Connect the fuel feed hose (A) Fuel Line/Quick-Connect Fitting Installation, then install the quick-connect fitting cover (B).
21. Install the front warm up TWC Warm Up TWC Removal/Installation and the rear warm up TWC Warm Up TWC Removal/Installation.
22. Connect the following engine wire harness connectors, and install the wire harness clamps to the cylinder head;
- Six injector connectors
- Knock sensor connector
- ECT sensor 1 connector
- Engine mount control solenoid valve connector
- EGR valve connector
- CMP sensor connector
- Rocker arm oil control solenoid connector
- Rocker arm oil pressure switch connector
- Two A/F sensor connectors
- Two secondary HO2S connectors
23. Install the six ignition coils Service and Repair.
24. Install the intake manifold.
25. Install the alternator.
26. Do the battery terminal reconnection procedure.
27. After installation, check that all tubes, hoses, and connectors are installed correctly.
28. 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.
29. Refill the radiator with engine coolant, and bleed the air from the cooling system.
30. Check for fluid leaks.
31. Do the PCM idle learn procedure PCM Idle Learn Procedure.
32. Do the CKP pattern clear/CKP pattern learn procedure.
33. Inspect the idle speed Testing and Inspection.
34. Inspect the ignition timing Testing and Inspection.