Cylinder Head Installation

Cylinder Head Installation
Install 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 the 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.
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 seep 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.
9. Install the timing belt.
10. Adjust the valve clearance.
11. Install the cylinder head cover.
12. Install the exhaust manifold and tighten the nuts in a crisscross pattern in two or three steps, beginning with the inner nut. Always use new exhaust manifold gasket.
13. Install the nuts securing the exhaust pipe A and exhaust manifold, then install the cover on the exhaust manifold.





14. Install the water passage (A). Always use a new O-ring (B) and new gaskets (C).








15. Install the fuel rails.





16. Install the vacuum hoses (A) on the intake air bypass control thermal valve (B).








17. Install the heater hoses.





18. Install the upper radiator hose (A) and lower radiator hose (B).
19. Install the intake manifold.
20. Loosely install the P/S pump and P/S pump belt.
21. Adjust the P/S pump belt.
22. Install the alternator.
23. Install the alternator belt.








24. Install the fuel feed hose (A) and fuel return hose (B), using new washers (C).
25. Clean the battery posts and cable terminals with sandpaper, then assemble them and apply grease to prevent corrosion.
26. After installation, check that all tubes, hoses and connectors are installed correctly.
27. 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.
28. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open.
29. Perform the Powertrain Control Module (PCM) idle learn procedure.
30. Perform the power window control unit reset procedure ('02-03 models).
31. Inspect the idle speed.
32. Inspect the ignition timing.