Cylinder Head Installation
Cylinder Head Installation1. Clean the cylinder head and block surface.
2. Clean and install the oil control orifices (A) with new O-rings (B).
3. Install the dowel pins (C) and new cylinder head gaskets (D).
4. Clean the timing belt pulleys, timing belt guide plate, and the upper and lower covers.
5. Set the timing belt drive pulley to top dead center (TDC) by aligning the TDC mark (A) on the tooth of the timing belt drive pulley with the pointer (B) on the oil pump.
6. Set the camshaft pulleys to TDC by aligning the TDC marks (A) on the camshaft pulleys with the pointers (B) on the back covers.
7. Put the cylinder head onto the engine block.
8. Install the cylinder head bolts:
^ 6 point cylinder head bolt: Go to step 9
^ 12 point cylinder head bolt: Go to step 11
Note: Head bolt types must be all the same type on the cylinder head. Do not mix head bolt types.
Tightening sequence for 6 point head bolts
9. Apply new engine oil to the threads and flanges of the cylinder head bolts.
10. Tighten the cylinder head bolts sequentially in three steps.
NOTE: Perform each step twice.
1st Step Torque: 39 Nm (4.0 kgf-m, 29 ft. lbs.)
2nd Step Torque: 69 Nm (7.0 kgf-m, 51 ft. lbs.)
3rd Step Torque: 98.1 Nm (10.0 kgf-m, 72.3 ft. lbs.)
Use a beam-type torque wrench. When using a preset-type torque wrench, be sure to tighten slowly and not to overtighten. If a bolt makes any noise while you are torquing it, loosen the bolt, and retighten it from the first step, then go to step 16.
Tightening sequence for 12 point head bolts
11. Measure the diameter of each cylinder head bolt at point A and point B.
12. If either diameter is less than 11.3 mm (0.44 inch), replace the cylinder head bolt.
13. Apply engine oil to the threads and under the bolt heads of all cylinder head bolts.
14. Tighten the cylinder head bolts in sequence to 29 Nm (3.0 kgf-m, 22 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.
15. After torquing, tighten all cylinder head bolts in two steps (90° per step). If you are using a new cylinder head bolt, tighten the bolt an extra 90°, then go to step 15.
NOTE: Remove the cylinder head bolt if you tightened it beyond the specified angle, and go back to step 8 of the procedure. Do not loosen it back to the specified angle.
16. Install the front and rear warm up three way catalytic converter (WU-TWC).
17. Install the water passage (A). Always use a new O-ring (B) and new gaskets (C).
18. Tighten the bolt securing the harness bracket.
19. Set the new O-ring on the injectors, then install the fuel rails.
20. Install the ground cable (A).
21. Tighten the bolt (B) securing the harness bracket.
22. Install the heater hose (A) and water bypass hoses (B).
23. Install the upper radiator hose (A), and lower radiator hose (B).
24. Install the power steering (P/S) pump (A) and P/S hose bracket (B).
25. Install the timing belt.
26. Adjust the valve clearance.
27. Install the cylinder head covers.
28. Install the intake manifold.
29. Install the alternator.
30. Install the drive belt.
31. Install the fuel line.
32. Clean the battery posts and cable terminals with sandpaper. Assemble them and apply grease to prevent corrosion.
33. After installation, check that all tubes, hoses, and connectors are installed correctly.
34. Inspect for fuel leaks. Turn the ignition switch ON (II) (do not operate the starter) so 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.
35. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open.
36. Do the crankshaft position (CKP) pattern clear/CKP pattern learn procedure.
37. Inspect the idle speed.
38. Inspect the ignition timing.
39. Enter the anti-theft codes for the radio and the navigation system, then enter the customer's audio presets.
40. Set the clock.