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





3. Set the crankshaft to top dead center (TDC). Align the TDC mark (A) on the timing belt drive pulley with the pointer (B) on the oil pump.





4. Clean the camshaft pulley and set it to TDC.
1 The "UP" mark (A) on the camshaft pulley should be at the top.
2 Align the TDC marks (B) on the camshaft pulley with the top edge of the head.
5. Install the cylinder head on the block.
6. Apply new engine oil to the bolt threads and under the bolt heads of all the cylinder head bolts.
7. Tighten the cylinder head bolts sequentially in 3 steps.
Specified Torque
1st Step Torque: 20 Nm (2.0 kgf-m, 14 ft. lbs.)
2nd Step Torque: 49 Nm (5.0 kgf-m, 36 ft. lbs.)
3rd Step Torque: 67 Nm (6.8 kgf-m, 49 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.
8. Install the timing belt.
9. Adjust the valve clearance.
10. Install the fuel pressure regulator P2.





11. Install the exhaust manifold (A) with a new gasket (B). Loosely install the new nuts, then install the cover (C) and loosely install the new bolts.
12. Tighten the bolts/nuts in a crisscross pattern in two or three steps.
13. Install the exhaust pipe with new gasket (D).
14. Install the exhaust manifold bracket (E).
15. Loosely install the alternator.
16. Adjust the alternator-compressor belt tension.
17. Loosely install the power steering (P/S) Pump belt and pump.
18. Adjust the P/S pump belt.
19. Install the A/C hose bracket and P/S hose bracket.





20. Install the connecting pipe.





21. Install the wire harness cramp.
22. Connect the heater hose, lower radiator hose, upper radiator hose, and ground cable.
23. Install the intake manifold.
24. Install the air cleaner housing.
25. Install the intake resonator.
26. Install the throttle cable.
27. Adjust the throttle cable.
28. Install the cruise control actuator cable.
29. Adjust the cruise control actuator cable.
30. Do the leak inspection.
31. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open.
32. Clean the battery posts and cable terminals with sand paper, then assemble them and apply grease to prevent corrosion.
33. Enter the anti-theft code for the radio, then enter the customer's radio station presets.
34. Set the clock.
35. Do the powertrain control module (PCM) idle learn procedure.