Cylinder Head Installation

Installation





1. Make sure the crankshaft pulley is at top dead center (TDC).
2. Clean the cylinder head and block surfaces.





3. Apply liquid gasket, part No. 08718-0009, to the shaded areas (A) of the cylinder head gasket mating surface of the block and oil pump.





4. Install the dowel pins (A) and new cylinder head gasket (B).





5. Apply liquid gasket, part No. 08718-0009, to the cylinder head mating surface of the block and oil pump along the broken line.
6. Install the cylinder head on the block.
7. Apply engine oil to the threads and under the heads of all the cylinder head bolts.





8. Tighten the cylinder head bolts in sequence to 39 Nm (4.0 kgf-cm, 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.
9. Turn the cylinder head bolts 90°.
10. Tighten the 6 mm bolts (A) to 12 Nm (1.2 kgf-cm, 8.7 ft. lbs.).





11. Place the camshaft sprocket into the cylinder head.





12. Install the cam chain on the camshaft sprocket, then fit the camshaft sprocket on the camshaft.
13. Turn the camshaft sprocket counterclockwise to relieve cam chain free play, and check the alignment of the TDC mark (A) on the camshaft sprocket with the cylinder head surface. If the camshaft sprocket is not positioned at TDC, remove the camshaft sprocket from the camshaft and reposition the cam chain to bring the camshaft sprocket to TDC.





14. Hold the camshaft with an open-end wrench, then tighten the camshaft sprocket mounting bolt.
Specified torque: 56 Nm (5.7 kgf-cm, 41 ft. lbs.)





15. Put the new cylinder head plug into the cylinder head.





16. Press the rod to pump the oil out of the timing chain auto-tensioner.





17. Install the new O-ring (A) into the spacer (B). Set the spacer and new gasket (C) on the cam chain auto-tensioner (D), then tighten the bolt and nuts equally while pressing the timing chain auto-tensioner against the cylinder head.
18. Adjust the valve clearance.
19. Install the cylinder head cover.
20. Install the dipstick.





21. Install the three way catalytic converter (A) using new gaskets (B) and new nuts (C).





22. Install the heater hoses.





23. Install the connecting pipes (A) using new O-rings (B).
24. Install the upper radiator hose (C).





25. Install the exhaust gas recirculation (EGR) plate (A) and intake manifold (B) using a new gasket (C) and new O-rings (D).





26. Install the positive crankcase ventilation (PCV) hose (A) and vacuum hose (B).





27. Install the fuel return hose (A), and install the fuel feed hose (B) with new washers (C).





28. Install the brake booster vacuum hose (A), evaporative emission (EVAP) control canister hose (B), water bypass hoses (C), and vacuum hose (D).





29. Install the air cleaner housing/intake air duct assembly (A), then install the brake booster vacuum hose bracket (B) and breather pipe (C).
30. Install the throttle cable, then adjust the cable.
31. After installation, check that all tubes, hoses and connectors are installed correctly.





32. Install the engine cover.
33. After assembly, wait at least 30 minutes before filling the engine with oil.
34. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open.
35. Inspect for fuel leaks. Turn ON (II) the ignition switch (do not operate the starter) so that the fuel pump runs for approximately two 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.
36. Start the engine. Hold the engine at 3500 rpm with no load for 10 minutes.
37. The IMA Battery Level indicator should read full.
38. Perform the engine control module (ECM) idle learn procedure.
39. Enter the customer's radio station presets.
40. Set the clock.