Cylinder Head Installation
InstallationInstall 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 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 three steps.
1st step torque: 20 Nm (2.0 kgf-cm, 14 ft. lbs.)
2nd step torque: 49 Nm (5.0 kgf-cm, 36 ft. lbs.)
3rd step torque: 67 Nm (6.8 kgf-cm, 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 1st step.
8. Install the timing belt.
9. Adjust the valve clearance.
10. Install the cylinder head cover.
11. Install the intake manifold (A) and tighten the bolts/nuts in a crisscross pattern in two or three steps, beginning with the inner nut. Always use a new intake manifold gasket (B).
12. Tighten the three nuts securing the intake manifold and brackets.
13. Install the new exhaust manifold gasket (A) and exhaust manifold (B). Loosely install the new nuts, then install the cover (C) and loosely install the new bolts.
14. Tighten the bolts/nuts in a crisscross pattern in two or three steps.
15. Install the exhaust pipe with a new gasket (D).
16. Install the exhaust manifold bracket (E) (D17A1, D17A6 engines).
17. Install the A/C hose bracket (A) and power steering (P/S) hose bracket (B).
18. Loosely install the alternator.
19. Adjust the alternator belt tension or the alternator-A/C compressor belt tension.
20. Loosely install the P/S pump belt and pump.
21. Adjust the P/S pump belt.
22. Install the connecting pipe (A) with a new O-ring (B).
23. Install the ground cable (A), upper radiator hose (B), lower radiator hose (C), heater hose (D) and water bypass hose (E).
24. Install the evaporative emission (EVAP) canister hose.
25. Install the brake booster vacuum hose (A) and positive crankcase ventilation (PCV) hose (B).
26. Install the air cleaner housing (A), then connect the Intake Air Temperature (IAT) sensor connector (B) and breather hose.
27. Install the intake resonator.
28. Install the cruise control cable, then adjust the cable.
29. Install the throttle cable, then adjust the cable.
30. After installation, check that all tubes, hoses and connectors are installed correctly.
31. Clean the battery posts and cable terminals with sandpaper, then assemble them and apply grease to prevent corrosion.
32. Inspect for fuel leaks. Turn ON (II) the ignition switch (do not operate the starter) so that 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.
33. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open.
34. Enter the anti-theft code for the radio, then enter the customer's radio station presets.