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. Install the new cylinder head gasket (A) and dowel pins (B) on the engine block. Always use a new cylinder head gasket.





3. Set the crankshaft to top dead center (TDC). Align the TDC mark (A) on the crankshaft sprocket with the pointer (B) on the engine block.
4. Install the cylinder head on the block.





5. Measure the diameter of each cylinder head bolt at point A and point B.
6. If either diameter is less than 10.6 mm (0.42 inch), replace the cylinder head bolt.
7. Apply new engine oil to the bolt threads and flange of all the cylinder head bolts.





8. Tighten the cylinder head bolts in sequence to 39 Nm (4.0 kgf-m, 29 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.





9. 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 5 of the procedure. Do not loosen it back to the specified angle.

10. Install the rocker arm assembly.





11. Install the water bypass hose (A).
12. Tighten the connecting pipe mounting bolt (B) and water bypass line mounting bolts (C), then install the harness holder (D) on the bracket.





13. Install the upper radiator hose (A) and heater hose (B).





14. Install the water bypass hose.
15. Install the intake manifold.
16. Install the exhaust manifold.
17. Install the cam chain.
18. K20A3 engine: Install the fuel feed line.
19. Adjust the valve clearance.
20. Install the drive belt.
21. Clean the battery posts and cable terminals with sandpaper, then assemble them and apply grease to prevent corrosion.
22. After installation, check that all tubes, hoses and connectors are installed correctly.
23. 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.
24. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open.
25. 2002-2004 models: Do the engine control module (ECM)/powertrain control module (PCM) idle learn procedure.
26. 2005-2006 models: Do the crankshaft position (CKP) pattern clear/CKP pattern learn procedure.
27. Do the power window control unit reset procedure.
28. Inspect the idle speed.
29. Inspect the ignition timing.
30. Enter the anti-theft code for the radio, then enter the customer's audio presets.
31. Set the clock.