Cylinder Head Installation
Cylinder Head Installation1. Clean the cylinder head and engine 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. Apply new engine oil to the threads and flanges of the cylinder head bolts.
9. 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 when being torqued, loosen the bolt, and retighten-it from the 1st step.
10. Install the timing belt.
11. Adjust the valve clearance.
12. Install the cylinder head covers.
13. Install the water passage.
14. Install the front warm up three way catalytic converter (front WU-TWC) and rear warm up three way catalytic converter (rear WU-TWC).
15. Install the fuel rails.
16. Install the connector bracket to the front cylinder head.
17. Install the harness clamp bracket to the rear cylinder head.
18. Install the upper radiator hose (A) and lower radiator hose (B).
19. Install the purge joint.
20. Connect the fuel feed hose, then install the quick-connect fitting cover (A).
21. Connect the engine wire harness connectors, and install the wire harness clamps to the cylinder head.
- Six injector connector
- Engine coolant temperature (ECT) sensor 1 connector
- Engine coolant temperature (ECT) sensor 2 connector
- Crankshaft position (CKP) sensor connector
- Exhaust gas recirculation (EGR) valve connector
- VTEC solenoid valve connector
- VTEC oil pressure switch connector
- Oil pressure switch connector
- Two air fuel ratio (A/F) sensor connectors
- Two secondary heated oxygen sensor (secondary HO2S) connectors
22. Install the intake manifold.
23. Install the alternator.
24. Install the power steering (P/S) pump (A) and P/S hose bracket (B).
25. Install the drive belt.
26. Clean the battery posts and cable terminals with sandpaper, Assemble them and apply grease to prevent corrosion.
27. After installation, check that all tubes, hoses and connectors are installed correctly.
28. 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.
29. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open.
30. Do the crankshaft position (CKP) pattern clear/CKP pattern learn procedure.
31. Do the power window control unit reset procedure.
32. Inspect the idle speed.
33. Inspect the ignition timing.
34. Enter the anti-theft codes for the radio and the navigation system, then enter the customer's audio presets.
35. Set the clock.