Installation

CYLINDER HEAD ASSEMBLY

INSTALLATION

NOTE:
^ Thoroughly clean all parts to be assembled.
^ Always use a new head and manifold gasket.
^ The cylinder head gasket is a metal gasket. Take care not to bend it.
^ Rotate the crankshaft, set the No. 1 piston at TDC.





1. Install the cylinder head gaskets on the cylinder block.

NOTE: Be careful of the installation direction.

2. Place the cylinder head quietly in order not to damage the gasket with the bottom part of the end.
3. Install cylinder head bolts.
Tightening torque 25 Nm (250 kgf-cm, 18 ft. lbs.) + 60° + 45°
1) Apply a light coat if engine oil on the threads and under the heads of the cylinder head bolts.
2) Install the plate washer to the cylinder head bolt.





3) Install and uniformly tighten the cylinder head bolts on each cylinder head in several passes and in the sequence shown, then repeat for the other side, as shown.





If only one of the cylinder head bolts dose not meet the torque specification, replace the cylinder head bolt.
4) Retighten the cylinder head bolts by 60° in the numerical order shown.
5) Retighten the cylinder head bolts by 45° in the numerical order shown.





4. Install the water pipe and water temperature control assembly (A).





5. Install the timing bearing rear cover (A).
6. Install the camshafts.





1) Align the camshaft timing chain with the intake timing chain sprocket and exhaust timing chain sprocket as shown.





2) Install the camshaft (A).





3) Install the camshaft bearing caps (A).

NOTE: Apply new engine oil to the thrust portion and journal of the camshafts. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.





7. Using the SST (09214-21000), install the camshaft bearing oil seal.
8. Install the camshaft sprocket.
1) Temporarily install the camshaft sprocket bolts.
2) Hold the hexagonal head wrench portion of the camshaft with a wrench, and tighten the camshaft sprocket bolts.
Tightening torque
Camshaft sprocket bolt 90 - 110 Nm (900 - 1100 kgf-cm, 65 - 80 ft. lbs.)
9. Install semi-circular packing.
10. Install the cylinder head cover.





1) Install the cylinder head cover gasket (A) in the groove of the cylinder head cover (B).

NOTE: Before installing the head cover gasket, thoroughly clean the head cover gasket and the groove. When installing, make sure the head cover gasket is seated securely in the comers of the recesses with no gap.

2) Apply liquid gasket to the head cover gasket at the corners of the recess.

NOTE:
^ Use liquid gasket, Loctite No.5699.
^ Check that the mating surfaces are clean and dry before applying liquid gasket.
^ After assembly, wait at least 30 minutes before filling the engine with oil.








3) Install the cylinder head covers (A) with the 16 bolts. Uniformly tighten the bolts in several passes.
11. Install the spark plug cable.
12. Install the timing belt.
13. Install the exhaust manifold.
14. Install the power steering pump.
15. Install the intake manifold.





16. Install the PCV hose (A).
17. Install the accelerator cable.





18. Install the brake booster vacuum hose (A).
19. Install the PCSV hose.





20. Install the fuel inlet hose (A).
21. Install the engine wire harness connectors and wire harness clamps to the cylinder head and the intake manifold.





1) Three fuel injector connectors (A).
2) Oxygen sensor connector (D).
3) Crankshaft position sensor connector (C).
4) Ignition coil connector (B).





5) ECT sensor connector (A).
6) CMP (Camshaft position sensor) connector (G).
7) Knock sensor connector (F).
8) Injector connector (E).
9) PCSV (Purge Control Solenoid Valve) connector (C).
10) ISA connector (B).





11) TPS connector (A).





22. Install the heater hoses (A).





23. Install the upper radiator hose (A) and lower radiator hose (B).
24. Install the intake air hose and air cleaner assembly.
1) Install the intake air hose and air cleaner assembly.
2) Connect the breather hose from air cleaner hose.
3) Connect the NS connector.
25. Install the engine cover.





26. Connect the negative terminal to the battery.
27. Fill with engine coolant.
28. Start the engine and check for leaks.
29. Recheck engine coolant level and oil level.