Cylinder Head Installation

Cylinder Head Installation
Install the cylinder heads in the reverse order of removal:
1. Clean the cylinder heads 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 drive pulley.
5. Set the timing belt drive pulley to 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 flange of the cylinder head bolts.





8. Tighten the cylinder head bolts sequentially in three steps. 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.
9. Install the exhaust manifold and tighten the nuts in a crisscross pattern in two or three steps, beginning with the inner nut. Always use a new exhaust manifold gasket.
10. Install exhaust pipe A and bracket, then install the cover.
11. Install the timing belt.
12. Adjust the valve clearance.





13. Install the cylinder head covers.

NOTE:
^ Before installing the cylinder head cover, clean the cylinder head contacting surfaces with a shop towel.
^ Take care not to damage the spark plug seals when installing the cylinder head cover.
^ Visually check the spark plug seals for damage.
^ Replace any washer that is damaged or deteriorated.





14. Tighten the nuts in two or three steps. In the final step, tighten all nuts, in sequence, to 12 Nm (1.2 kgf-m, 8.7 ft. lbs.).





15. Install the water passage (A). Always use a new 0ring (B) and new gaskets (C).





16. Install the intake manifold. Tighten the bolts and nuts sequentially in two or three steps. Always use a new intake manifold gasket.
Specified torque:
8 x 1.25 mm 22 Nm (2.2 kgf-m, 16 ft. lbs.)
17. After installation, check that all tubes, hoses and connectors are installed correctly.
18. Enter the anti-theft code for the radio, then enter the customer's radio station presets.