Cylinder Head Installation
Cylinder Head Installation1. 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 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.
7. Apply new 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-cm, 29 ft. lbs.)
2nd step torque: 69 Nm (7.0 kgf-cm, 51 ft. lbs.)
3rd step torque: 98.1 Nm (10.0 kgf-cm, 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 water passage (A). Always use a new O-ring (B) and new gaskets (C).
10. Install the front and rear warm up three way catalytic converter (WU-TWC).
11. Set the new O-rings to the injectors, then install the fuel rails.
12. Connect the fuel feed hose, then install the quick-connect fitting cover (A).
13. Tighten the bolt (A) securing the harness holder.
14. Tighten the bolt (B) securing the harness bracket.
15. Tighten the bolt securing the harness bracket.
16. Install the heater hose (A) and water bypass hose(s) (B).
17. Install the upper radiator hose (A) and lower radiator hose (B).
18. Install the power steering (P/S) pump (A) and P/S hose bracket (B).
19. Install the timing belt.
20. Adjust the valve clearance.
21. Install the cylinder head covers.
22. Install the intake manifold.
23. Install the alternator.
24. Install the drive belt.
25. Clean the battery posts and cable terminals with sandpaper. 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. Inspect the idle speed.
30. Inspect the ignition timing.
31. Enter the anti-theft codes for the radio and the navigation system, then enter the customer's XM radio channel presets.
32. Set the clock.