Cylinder Head Installation
  1. Clean the cylinder head and the block surface.
  1. Install a new coolant separator (A) in the engine block whenever the engine block is replaced.
  1. Install the new cylinder head gasket (B) and the dowel pins (C) on the engine block. Always use a new cylinder head gasket.
  1. Set the crankshaft to top dead center (TDC). Align the TDC mark (A) on the crankshaft sprocket with the pointer (B) on the engine block.
  1. Set the camshaft TDC. The ‘‘UP'' mark (A) on the camshaft sprocket should be at the top, and the TDC grooves (B) on the camshaft sprocket should line up with the top edge of the head.
  1. Install the cylinder head on the engine block.
  1. Measure the diameter of each cylinder head bolt at point A and point B.
  1. If either diameter is less than 10.6 mm (0.42 in.), replace the cylinder head bolt.
  1. Apply new engine oil to the threads and under the bolt heads of all cylinder head bolts.
  1. Tighten the cylinder head bolts in sequence to 39 N·m (4.0 kgf·m, 29 lbf·ft). Using 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.
  1. 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 60 °.
    NOTE: Remove the cylinder head bolt if you tightened it beyond the specified angle, and go back to Step 7 of the procedure. Do not loosen it back to the specified angle.
  1. Connect the following engine wire harness connectors, and install the wire harness clamps to the cylinder head:
    • Four injector connector
    • Engine coolant temperature (ECT) sensor 1 connector
    • Air fuel ratio (A/F) sensor connector
    • Secondary heated oxygen sensor (secondary HO2S) connector
    • Exhaust gas recirculation (EGR) valve connector
    • Rocker arm oil control solenoid connector
  1. Install the upper radiator hose (A), the heater hose (B), and the engine mount control solenoid valve (C).
  1. Install the harness holder (A) on the cylinder head.
  1. Install the harness clamps (A) and the positive crankcase ventilation (PCV) hose (B).
  1. After installation, check that all tubes, hoses and connectors are installed correctly.
  1. Inspect for fuel leaks. Turn the ignition switch to ON (II) (do not operate the starter) so the fuel pump runs for about 2 seconds and pressurizes the fuel line. Repeat this operation three times, then check for fuel leakage at any point in the fuel line.