1. | Clean the cylinder head and block surface. |
2. | Install the new cylinder head gasket (A) and dowel pins (B) on the cylinder block. Always use a new cylinder head gasket.
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3. | Check that the crankshaft keyway is facing up. |
4. | Install the cylinder head on the block. |
5. | Apply engine oil to the threads and under the bolt heads of all cylinder head bolts. |
6. | Tighten the cylinder head bolts in sequence to 29 N·m (3.0 kgf·m, 22 lbf·ft). 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.
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7. | Tighten all cylinder head bolts an additional 130°. |
8. | Install the cam chain guide mounting bolt.
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9. | Install the cam chain to the camshaft sprocket by alignment the reference mark (A), then install the camshaft sprocket on the camshaft.
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10. | Hold the camshaft with an open-end wrench, then tighten the bolt.
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11. | Loosely install the crankshaft pulley. |
12. | Apply engine oil to the slider surface of the cam chain tensioner slider through the oil return hole in the cylinder head.
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13. | Hold the crankshaft pulley and set the socket wrench (A) on the camshaft sprocket bolt.
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14. | Turn the camshaft clockwise to compress the cam chain tensioner, then remove the 6 x 1.0 mm bolt (B)NOTE:
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15. | Check the chain case oil seal for damage. If the oil seal is damaged, replace the chain case oil seal. |
16. | Remove old liquid gasket from the chain case mating surfaces, bolts, and bolt holes. |
17. | Clean and dry the chain case mating surfaces. |
18. | Apply liquid gasket, P/N 08C70-K0234M, 08C70- K0334M or 08C70-X0331S, to the cylinder block mating surface of the chain case and the inner threads of the holes.NOTE:
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19. | Apply liquid gasket, P/N 08C70-K0334M or 08C70- X0331S, to the oil pan mating surface of the chain case and the inner threads of the holes.NOTE:
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20. | Set the edge of the chain case (A) to the edge of the oil pan (B), then install the chain case on the cylinder block (C). NOTE: When installing the chain case, do not slide the bottom surface on the oil pan mounting surface.
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21. | Install the harness clamps (A), and connect the Crankshaft Position (CKP) sensor connector. |
22. | Install the side engine mount/bracket assembly, then install the ground cable. |
23. | Install the crankshaft pulley. |
24. | Install the cylinder head cover. |
25. | Install the water pump pulley. |
26. | Install the idler pulley (with A/C compressor). |
27. | Install the alternator bracket mounting bolt. |
28. | Install the drive belt and adjust it. |
29. | Install the connecting pipe (A), using a new O-ring (B).
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30. | Install the water bypass hose (C) and Positive Crankcase Ventilation (PCV) hose (D). |
31. | Install the harness holder (A), then install harness holder mounting bolt (B), ground cable (C) and air cleaner housing bracket (D).
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32. | Install the fuel rail. |
33. | Install the exhaust manifold. |
34. | Install the intake manifold. |
35. | Install the heater hoses.
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36. | Install the upper radiator hose (A) and lower radiator hose (B).
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37. | Install the water bypass hoses.
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38. | Install air cleaner housing. |
39. | Adjust the valve clearance. |
40. | After installation, check that all tubes, hoses and connectors are installed correctly. |
41. | Inspect for fuel leaks. Turn the ignition switch ON (II) (do not operate the starter) so that 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. |
42. | Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open. |
43. | Inspect the idle speed. |
44. | Inspect the ignition timing. |