Cylinder Head Installation
InstallationInstall the cylinder head in the reverse order of removal:
1. Clean the cylinder head and block surface.
2. Clean and install the oil control orifices (A) with new O-rings (B).
3. Install the dowel pins (C) and new cylinder head gaskets (D).
4. Clean the timing belt drive pulley.
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. Clean the camshaft pulleys. 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. Apply clean engine oil to the threads and flanges of the cylinder head bolts.
8. Tighten the cylinder head bolts sequentially in three steps.
NOTE: Perform each step twice.
1st step torque: 39 Nm (4.0 kgf-m, 29 ft. lbs.)
2nd step torque: 69 Nm (7.0 kgf-m, 51 ft. lbs.)
3rd step torque: 98.1 Nm (10.0 kgf-m, 72.3 ft. lbs.)
Use a beam-type torque wrench. When using a preset-type torque wrench, be sure to tighten slowly and not to overtighten.
If a bolt makes any noise while you are torquing it, loosen the bolt, and retighten it from the 1st step.
Cylinder Head Bolts:
CYLINDER HEAD BOLTS TORQUE SEQUENCE
9. Install the exhaust manifold and tighten the nuts in a crisscross pattern in two or three steps, beginning with the inner nut. Always use a new exhaust manifold gasket.
10. Install the splash shield.
11. Install the timing belt.
12. Adjust the valve clearance.
13. Install the cylinder head cover.
NOTE:
^ Before installing the cylinder head cover, clean the cylinder head contacting surfaces with a shop towel. Take care not to damage the spark plug seal when installing the cylinder head cover.
^ Visually check the spark plug seal for damage.
^ Replace any washer that is damaged or deteriorated.
14. Tighten the bolts in two or three steps. In the final step, tighten all bolts, in sequence, to 12 Nm (1.2 kgf-m, 8.7 ft. lbs.).
15. Install the water passage (A). Always use a new O-ring (B) and new gaskets (C).
16. Install the fuel rails.
17. Install the vacuum hoses (A) on the intake air bypass control thermal valve (B).
18. Install the heater hoses.
19. Install the upper radiator hoses (A) and lower radiator hose (B).
Intake Manifold:
20. Install the intake manifold. Tighten the bolts and nuts sequentially in two or three steps. Always use a new intake manifold gasket.
Specified torque:
8 x 1.25 mm 22 Nm 12.2 kgf-m, 16 ft. lbs.)
Upper Cover Bolts:
21. Install the upper cover. Tighten the bolts and nuts sequentially in two or three steps. Always use a new gasket.
Specified torque:
6 x 1.0 mm 12 Nm (1.2 kgf-m, 8.7 ft. lbs.)
22. Install the wire harness holder, then secure the bolts.
23. Install the Intake Manifold Runner Control (IMRC) actuator (A), then connect the IMRC actuator connector (B) (J32A2 engine).
24. Install the Power Steering (P/S) hose clamp (C).
25. Loosely install the P/S pump and P/S pump belt.
26. Adjust the P/S pump belt.
27. Install the alternator.
28. Install the alternator belt.
29. Install the ignition coils.
30. Install the fuel feed hose (A) and fuel return hose (B), using new washers (C).
31. Install the brake booster vacuum hose (A), vacuum hoses (B) and Positive Crankcase Ventilation (PCV) hose (C).
32. Install the breather hose (A) and water bypass hose (B).
33. Install the throttle cable, then adjust the cable.
34. Install the cruise control cable, then adjust the cable.
35. Install the intake air duct (A), then install the vacuum hose (B) and breather pipe (C).
J32A1 engine, J32A2 engine (M/T)
J32A2 engine (A/T)
36. Install the Evaporative Emission (EVAP) canister hose (D).
37. Tighten the bolt (A) securing the TCS control valve bracket. Connect the TCS control valve angle sensor connector (B), TCS control valve actuator connector (C) and water bypass hoses (D) on the TCS control valve assembly [J32A2 engine (A/T)].
38. Install the ignition coil cover (A) and intake manifold cover (B).
39. Install the strut brace.
40. Clean the battery posts and cable terminals with sandpaper, then assemble them and apply grease to prevent corrosion.
41. After installation, check that all tubes, hoses and connectors are installed correctly.
42. 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.
43. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open.
44. Perform the Engine Control Module (ECM)/ Powertrain Control Module (PCM) idle learn procedure.
45. Inspect the idle speed.
46. Inspect the ignition timing.
47. Perform the power window control unit reset procedure.
48. Enter the anti-theft code for the radio, then enter the customer's radio station presets.