| 1. | Clean the cylinder head and block surface. |
| 2. | Install the new coolant separator (A) in the engine block when replacing the engine block.
|
| 3. | Install the new cylinder head gasket (B) and dowel pins (C) on the engine block. Always use a new cylinder head gasket. |
| 4. | 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.
|
| 5. | 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.
|
| 6. | Install the cylinder head on the block. |
| 7. | Measure the diameter of each cylinder head bolt at point A and point B.
|
| 8. | If either diameter is less than 10.6 mm (0.42 in.), replace the cylinder head bolt. |
| 9. | Apply new engine oil to the threads and under the bolt heads of all cylinder head bolts. |
| 10. | Tighten the cylinder head bolts in sequence to 39 N·m (4.0 kgf·m, 29 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.
|
| 11. | 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 7 of the procedure. Do not loosen it back to the specified angle.
|
| 12. | Install the cam chain. |
| 13. | Adjust the valve clearance. |
| 14. | Install the cylinder head cover. |
| 15. | Install the thermostat housing. |
| 16. | Install the three way catalytic converter (TWC). |
| 17. | Connect the engine wire harness connectors, and install the wire harness clamps to the cylinder head.
|
| 18. | Install the upper radiator hose (A) and heater hose (B) (M/T).
|
| 19. | Install the upper radiator hose (A), heater hose (B), and water bypass hose (C) (A/T).
|
| 20. | Install the harness holder (A) on the cylinder head, then Install the air cleaner housing bracket (B).
|
| 21. | Install the harness clamps (A), and install the positive crankcase ventilation (PCV) hose to the clamp (B).
|
| 22. | Install the intake manifold. |
| 23. | Install the drive belt. |
| 24. | Clean the battery posts and cable terminals with sandpaper, then assemble them, and apply grease to prevent corrosion. |
| 25. | After installation, check that all tubes, hoses, and connectors are installed correctly. |
| 26. | 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. |
| 27. | Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open. |
| 28. | Do the crankshaft position (CKP) pattern clear/CKP pattern learn procedure. |
| 29. | Do the power window control unit reset procedure. |
| 30. | Inspect the idle speed. |
| 31. | Inspect the ignition timing. |
| 32. | Enter the anti-theft code for the radio or the navigation system, then enter the customer's audio presets. |
| 33. | Set the clock. |