| 1. | Install the new coolant separator in the engine block when replacing the engine block.
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| 2. | Clean the cylinder head and block surface. |
| 3. | Install the new cylinder head gasket (A) and dowel pins (B) on the engine block. Always use a new cylinder head gasket.
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| 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.
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| 5. | Install the cylinder head on the block. |
| 6. | Measure the diameter of each cylinder head bolt at point A and point B.
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| 7. | If either diameter is less than 10.6 mm (0.42 in.), replace the cylinder head bolt. |
| 8. | Apply engine oil to the threads and under the bolt heads of all cylinder head bolts. |
| 9. | 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.
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| 10. | 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 90 °. NOTE: Remove the cylinder head bolt if you tightened it beyond the specified angle, and go back to 6 of the procedure. Do not loosen it back to the specified angle.
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| 11. | Install the rocker arm assembly. |
| 12. | Install the cam chain. |
| 13. | Connect the engine wire harness connectors, and install the wire harness clamps to the cylinder head.
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| 14. | Install the bolt (A) securing the connecting pipe.
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| 15. | Install the water bypass hose (B). |
| 16. | Install the upper radiator hose (A) and heater hoses (B).
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| 17. | Install the harness holder bracket (A), then install the harness holder (B).
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| 18. | Install the positive crankcase ventilation (PCV) hose (A) and ground cable (B).
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| 19. | Connect the fuel feed hose, then install the quick-connect fitting cover (A).
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| 20. | Install the evaporative emission (EVAP) canister hose (A) and brake booster vacuum hose (B).
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| 21. | Install the exhaust manifold. |
| 22. | Install the intake manifold. |
| 23. | Install the drive belt. |
| 24. | Install the air cleaner housing. |
| 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 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. |
| 27. | Refill the radiator with engine coolant, and bleed the air from the cooling system with the heater valve open. |
| 28. | Inspect the idle speed. |
| 29. | Inspect the ignition timing. |