Cylinder Head Cover Removal and Installation (1.5 L Engine): Installation

NOTE: How to read the torque specifications .

1. Cylinder Head Cover - Install

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   1. Thoroughly clean the head cover gasket (A) and the groove of the cylinder head cover (B). NOTE: Check and, if necessary, replace the head cover gasket. 2. Check the spark plug seals (C) for damage. If any seals are damaged, replace the cylinder head cover. 3. Install the head cover gasket in the groove of the cylinder head cover. Make sure the head cover gasket is seated securely.

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   4. Apply liquid gasket to the cam chain case, the high pressure fuel pump base, and the cylinder head mating areas. 5. Apply a light coat of new engine oil to the lip of the spark plug seals (A). 6. Set the spark plug seals on the spark plug tubes. Place the cylinder head cover (B) on the cylinder head, then slide the cylinder head cover slightly back and forth to seat the head cover gasket. 7. Inspect the spark plug seals for damage.

   Fig 1: Cylinder Head Cover Bolts In Sequence

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   8. Tighten the bolts in two steps. In the final step, torque all bolts in sequence to 7.0 N.m (0.71 kgf.m, 5.2 lbf.ft).

2. PCV Valve - Install

   1. If the PCV valve was removed, install the PCV valve.

3. Turbocharger Bypass Control Valve Solenoid Pipe - Install

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   1. Install the turbocharger bypass control valve solenoid pipe (A). 2. Connect the hoses (B).

4. Breather Hose, PCV Hose, and Harness Holder - Install

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   1. Connect the breather hose (A) and the PCV hose (B). 2. Install the harness holders (C) and the harness clips (D). 3. Connect the connectors (E).

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   NOTE (with break head band):  When installing a new break head band, do the following procedures. 4. Tighten the break head bolt until the bolt head (A) is twisted off completely. NOTE: Do not use an air tool. 5. Make sure the stopper end (B) contacts to the housing end (C) after tightening the break head bolt.

5. Turbocharger Water Return Pipe - Install

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   1. Install the turbocharger water return pipe (A) and the cylinder head cover heat insulator (B). 2. Install the air cleaner stay (C).

6. Ignition Coil - Install