Cylinder Head Installation
Cylinder Head Installation1. Clean the cylinder head and engine block surface.
2. Clean and install the oil control orifices (A) with new O-rings (B).
3. Install the dowel ping (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. Apply new engine oil to the threads and flanges of the cylinder head bolts.
9. Tighten the cylinder head bolts sequentially in three steps.
NOTE: Perform each step twice.
1st Step Torque: 39 Nm (4.01 kgf-m, 29 ft. lbs.)
2nd Step Torque: 69 Nm (7.01 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.
10. Install the timing belt.
11. Adjust the valve clearance.
12. Install the cylinder head cover.
13. Install the front and rear warm up three-way catalytic converter (WU-TWC).
14. Install the water passage (A). Always use a new O-ring (B) and new gaskets (C).
15. Set the new O-rings to the injectors, then install the fuel rails.
16. Install the evaporative emission (EVAP) canister hose joint with bracket,
17. Connect the fuel quick-connect fitting (A), then install the fuel quick-connect fitting cover (B).
18. Tighten the bolt securing the harness bracket.
19. Tighten the bolt securing the harness bracket.
20. Install the heater hose (A) and water bypass hose (B).
21. Install the upper radiator hose (A) and lower radiator hose (B).
22. Install the intake manifold.
23. Install these engine wire harness connectors and wire harness clamps to the cylinder head:
- Six injector connectors
- Engine coolant temperature (ECT) sensor 1 connector
- Engine coolant temperature (ECT) sensor 2 connector
- Camshaft position (CMP) sensor connector
- Crankshaft position (CKP) sensor A/B connector
- Exhaust gas recirculation (EGR) valve connector
- VTEC solenoid valve connector
- 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
24. Install the power steering (P/S) pump (A), and tighten the bolt (B) securing the P/S hose bracket.
25. Install the alternator.
26. Install the six ignition coils.
27. Install the drive belt.
28. Clean the battery posts and cable terminals with sandpaper, then assemble them and apply grease to prevent corrosion.
29. After installation, check that all tubes, hoses, and connectors are installed correctly.
30. 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.
31. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open.
32. Do the crankshaft (CKP) pattern clear/CKP pattern learn procedure.
33. Do the powertrain control module (PCM) idle learn procedure and power window control unit reset procedure.
34. Inspect the idle speed.
35. Inspect the ignition timing.
36. Enter the anti-theft codes for the radio and the navigation system, then enter the customer's radio Station presets.
37. Set the clock.