Cylinder Head Installation
Cylinder Head InstallationInstall the cylinder head in the reverse order of removal:
1. Clean the cylinder head and the engine block surface.
2. Install the new cylinder head gasket (A) and the dowel pins (B) on the engine block. Always use a new cylinder head gasket.
3. Check that the crankshaft keyway is facing up.
4. Install the cylinder head on the engine block.
5. Measure the diameter of each cylinder head bolt at point A and point B.
6. If either diameter is less than 10.6 mm (0.42 inch), replace the cylinder head bolt.
7. Apply new engine oil to the threads and flange of all cylinder head bolts. Be sure to install the 165 mm long head bolt (A) in the location shown.
8. 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.
9. Tighten all cylinder head bolts an additional 130°
NOTE: Remove the cylinder head bolt if you tightened it beyond the specified angle, and go back to step 5 of the procedure.
10. Install the cam chain guide mounting top bolt.
11. Install the cam chain around the camshaft sprocket aligned with the ref6rence mark (A), then install the camshaft sprocket on the camshaft.
12. Hold the camshaft with an open-end wrench, then tighten the bolt.
13. Loosely install the crankshaft pulley.
14. Apply new engine oil to the sliding surface of the cam chain tensioner through the oil return hole in the cylinder head.
15. Hold the crankshaft pulley and set the socket wrench (A) on the camshaft sprocket bolt.
16. Turn the camshaft clockwise to compress the cam chain tensioner, then remove the 6 x 1.0 mm bolt (B).
NOTE:
^ Turning torque should not exceed 44 Nm (4.5 kgf-m, 33 ft. lbs.), when turning the camshaft.
^ Do not turn the camshaft counterclockwise.
17. Check the chain case oil seal for damage. If the oil seal is damaged, replace the chain case oil seal.
18. Remove any old liquid gasket from the chain case mating surfaces, bolts, and bolt holes.
19. Clean and dry the chain case mating surfaces.
20. Apply liquid gasket, P/N 08717-0004, 08718-0001, 08718-0002, 08718-0003, or 08718-0009, to the cylinder head and engine block mating surface of the chain case.
NOTE:
^ Apply a 1.5 mm wide bead of liquid gasket along the broken lines (A).
^ Apply a 3.0 mm wide bead of liquid gasket to the engine block upper surface contact areas (B) on the chain case.
21. Apply liquid gasket, P/N 08718-0001, 08718-0002, or 08718-0009 to the oil pan mating surface of the chain case.
NOTE:
^ Apply a 1.5 mm wide bead of liquid gasket along the broken lines (A).
^ Apply a 5.0 mm wide bead of liquid gasket to the shaded area (B).
NOTE: Do not install components if too much time has passed after applying the liquid gasket (for P/N 08718-0002, no more than 4 minutes, for all others, no more than 5 minutes). Instead, remove the old residue and reapply the liquid gasket.
22. Set the edge of the chain case (A) to the edge of the oil pan (B), then install the chain case on the engine block (C). Wipe off the excess liquid gasket on the oil pan and chain case mating area.
NOTE: When installing the chain case, do not slide the bottom surface on the oil pan mounting surface.
23. Install the dipstick tube (A) with a new O-ring (B). Disconnect the CKP sensor (C) and the harness clamps (D).
24. Install the side engine mount bracket, then tighten the mounting nuts in the numbered sequence shown.
25. Install the ground cable.
26. Install the crankshaft pulley.
27. Install the WU-TWC and the under-floor TWC.
28. Install the cylinder head cover.
29. Install the water pump.
30. Install the drive belt.
31. Install the upper radiator hose (A), the lower radiator hose (B), the water bypass hose (C), and the heater hoses (D).
32. Install the purge control solenoid stay bolts (A) and the fuel pipe bolt (B), then connect the purge joint to the clamp stay (C).
33. Install the clip (D), then connect the purge control solenoid valve connector (E).
34. Install the harness clamp (A), then disconnect the CMP sensor (B) and the ECT sensor 1 (C).
35. Install the connecting pipe (A) with a new O-ring (B). Install the harness clamp (C), then connect the knock sensor (D).
36. Install the intake manifold.
37. Install the air cleaner.
38. After installation, check that all tubes, hoses, and connectors are installed correctly.
39. 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.
40. Refill the radiator with engine coolant, and bleed the air from the cooling system with the heater valve open.
41. Do the crankshaft position (CKP) pattern clear/CKP pattern learn procedure.
42. Inspect the idle speed.
43. Inspect the ignition timing.