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. Put the cylinder head onto the engine block.
5. Clean the timing belt pulleys, timing belt guide plate, and the upper and lower covers.
6. 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.
7. Set the camshaft pulleys to TDC by aligning the TDC marks (A) on the camshaft pulleys with the pointers (B) on the back covers.
8. Install the cylinder head bolts:
^ 6 point bolt: Go to step 9
^ 12 point bolt: Go to step 11
Tightening sequence for 6 point bolts
9. Apply new engine oil to the threads and flanges of the cylinder head bolts.
10. Tighten the cylinder head bolts sequentially in three steps, then go to step 16.
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 first step.
Tightening sequence for 12 point bolts
11. Measure the diameter of each cylinder head bolt at point A and point B.
12. If either diameter is less than 10.6 mm (0.42 inch), replace the cylinder head bolt.
13. Apply new engine oil to the threads and under the bolt heads of all cylinder head bolts.
14. Tighten the cylinder head bolts in sequence to 29 Nm (30 kgf-m, 22 ft. lbs.). 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.
15. After torquing, tighten all cylinder head bolts in two steps (90° per step). 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 11 of the procedure. Do not loosen it back to the specified angle.
16. Install the timing belt.
17. Adjust the valve clearance.
18. Install the cylinder head covers.
19. Install the water passage (A). Always use a new O-ring (B) and new gaskets (C).
20. Install the front and rear warm up three way catalytic converter (WU-TWC).
21. Set the new O-rings to the injectors, then install the fuel rails.
22. Connect the fuel feed hose, then install the quick-connect fitting cover (A).
23. Tighten the bolt (A) securing the harness holder.
24. Tighten the bolt (B) securing the harness bracket.
25. Tighten the bolt securing the harness bracket.
26. Install the heater hose (A) and water bypass hose(s) (B).
27. Install the upper radiator hose (A) and lower radiator hose (B).
28. Install the engine wire harness connectors and wire harness clamps to the cylinder head.
^ Six injector connectors
^ Engine coolant temperature (ECT) sensor connector
^ Camshaft position (CMP) sensor connector
^ Crankshaft position (CKP) sensor A/B connector
^ Exhaust gas recirculation (EGR) valve connector
^ Rocker arm oil control solenoid (VTEC solenoid valve) connector
^ Rocker arm oil pressure switch (VTEC oil pressure switch) connector
^ Oil pressure switch connector
^ Two air fuel ratio (A/F) sensor connectors
^ Two secondary heated oxygen sensor (secondary HO2S) connectors
29. Install the power steering (P/S) pump (A) and P/S hose bracket (B).
30. Install the six ignition coils.
31. Install the intake manifold.
32. Install the alternator.
33. Install the drive belt.
34. Clean the battery posts and cable terminals with sandpaper. Assemble them and apply grease to prevent corrosion.
35. After installation, check that all tubes, hoses and connectors are installed correctly.
36. 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.
37. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open.
38. Do the crankshaft position (CKP) pattern clear/CKP pattern learn procedure.
39. Inspect the idle speed.
40. Inspect the ignition timing.
41. Enter the anti-theft codes for the radio and the navigation system, then enter the audio presets.
42. Set the clock.