Part 2

CYLINDER HEAD

COMPONENTS:

INSTALLATION (STEPS 36-77)
36. INSTALL ENGINE MOVING CONTROL ROD
37. INSTALL AIR CLEANER BRACKET
38. INSTALL RESERVOIR BRACKET
39. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY
40. INSTALL WATER OUTLET
a. Install 2 new gaskets to the 2 cylinder heads.
b. Install the water outlet together with water by-pass hose No. 1 and unlock the hose clamp.
c. Tighten the 2 bolts, 2 nuts and 2 washers.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
d. Install the clamp.
e. Connect the engine coolant temperature sensor connector.
f. Connect the radiator hose inlet.
41. CONNECT RADIATOR HOSE INLET

42. INSTALL INTAKE MANIFOLD
a. Install the intake manifold with the 9 bolts, 2 nuts and 2 washers. Using several steps, tighten the bolts and nuts uniformly in the sequence shown in the illustration.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
b. Retighten the water outlet mounting bolts and nuts.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
c. Install the ground cable with the nut.
Torque: 8.4 Nm (86 kgf-cm, 74 inch lbs.)
d. Connect the heater inlet water hose.
43. CONNECT FUEL PIPE SUB-ASSEMBLY NO. 1
44. INSTALL INTAKE AIR SURGE TANK
45. INSTALL EMISSION CONTROL VALVE SET
46. INSTALL W/CONVERTER INVERTER ASSEMBLY
47. INSTALL AIR CLEANER CASE W/RESONATOR
48. INSTALL AIR CLEANER CAP W/INLET
49. INSTALL COOL AIR INTAKE DUCT SEAL
50. INSTALL BATTERY CARRIER SUB-ASSEMBLY
51. INSTALL BATTERY
52. INSTALL SERVICE PLUG GRIP
53. INSTALL COWL TOP PANEL SUB-ASSEMBLY OUTER
54. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY
55. INSTALL COWL TOP VENTILATOR LOUVER SUBASSEMBLY
56. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH
57. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH
58. INSTALL ENGINE UNDER COVER NO. 2
59. INSTALL FRONT FENDER APRON SEAL RH
60. INSTALL FRONT FENDER SPLASH SHIELD SUBASSEMBLY RH
61. INSTALL ENGINE UNDER COVER NO. 1
62. INSTALL FRONT WHEEL RH
63. ADD ENGINE OIL
64. ADD COOLANT (HYBRID SIDE)
65. ADD COOLANT (ENGINE SIDE)
66. CHECK FOR ENGINE OIL LEAKS
67. CHECK FOR ENGINE COOLANT LEAKS (HYBRID SIDE)
68. CHECK FOR ENGINE COOLANT LEAKS (ENGINE SIDE)
69. CHECK FOR FUEL LEAKS
70. CHECK FOR EXHAUST GAS LEAKS
71. INSPECT IGNITION TIMING
72. INSPECT ENGINE IDLE SPEED
73. INSPECT COMPRESSION
74. INSPECT CO/HC
75. PERFORM INITIALIZATION
a. Some systems need initialization when reconnecting the battery cable.
76. INSTALL ENGINE ROOM COVER SIDE
77. INSTALL ENGINE ROOM SIDE LH COVER