Repair Procedures: Installation

WARNING: This page is about a different variant/trim than selected.

NOTE:

Thoroughly clean all parts to be assembled.
Always use a new cylinder head and manifold gasket.
Always use a new cylinder head bolt.
The cylinder head gasket is a metal gasket. Take care not to bend it.
Rotate the crankshaft, set the No. 1 piston at TDC.

Install the cylinder head assembly.

Before installing, remove the hardened sealant from the cylinder block and cylinder head surface.

Before installing the cylinder head gasket, apply sealant on the upper surface of the cylinder block and reassemble the gasket within five minutes.

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NOTE:

Refer to the image above for applying sealant.

Width: 2.0 ~ 3.0 mm (0.0787 ~ 0.1181 in.)

Position: 1.0 ~ 1.5 mm (0.0394 ~ 0.0591 in.)

Specification: TB 1217H or LOCTITE 5900H

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After installing the cylinder head gasket on the cylinder block, apply sealant on the upper surface of the cylinder head gasket and reassemble in five minutes.

Place the cylinder head carefully not to damage the gasket.

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Install the cylinder head bolts with washers.
1. Tighten the 10 cylinder head bolts, in several passes, in the sequence shown.
  Tightening torque:
  
  29.4 N.m (3.0 kgf.m, 21.7 lb-ft) + 90° + 90°
  
  Fig 1: Cylinder Head Bolts Tightening Sequence
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  CAUTION:
  - Always use new cylinder head bolts.
Install the head cover heat protector (A).
Tightening torque:

9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

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Install the rear hanger (A).

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Install the oil control valve (OCV).
(Refer to Fuel System - "CVVT OIL CONTROL VALVE (OCV) ")
Install the heater pipe.
(Refer to Cooling System - "WATER PIPE ")
Install the water control assembly, and bypass hose.
(Refer to Cooling System - "WATER TEMPERATURE CONTROL ASSEMBLY ")
Install the delivery pipe assembly.
(Refer to Fuel System - "DELIVERY PIPE ")
Install the intake manifold.
(Refer to Intake and Exhaust System - "INTAKE MANIFOLD ")
Install the turbo manifold.
(Refer to Intake and Exhaust System - "EXHAUST MANIFOLD ")
Install the cam shaft.
(Refer to Cylinder Head Assembly - "CAM SHAFT ")
Install the timing chain.
(Refer to Timing System - "TIMING CHAIN ")
Install the timing chain cover.
(Refer to Timing System - "TIMING CHAIN COVER )
Install the cylinder head cover.
(Refer to Cylinder Head Assembly - "Cylinder Head Cover ")
CAUTION:
- Do not reuse the disassembled gasket.
Install the vacuum pipe assembly (A).
Tightening torque:

9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

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Connect the heater hose (A).

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Connect the brake vacuum hose (A).

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Install in the reverse order of removal.
NOTE:
Perform the following:
- Refill engine with engine oil.
- Refill a radiator and a reservoir tank with engine coolant.
- Inspect for fuel leakage.
  - After assemble the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for approximately two seconds and fuel line pressurizes.
  - Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.
- Bleed air from the cooling system.
  - Start engine and let it run until it warms up. (until the radiator fan operates 3 or 4 times.)
  - Turn Off the engine. Check the level in the radiator, add coolant if needed. This will allow trapped air to be removed from the cooling system.
  - Put radiator cap on tightly, then run the engine again and check for leaks.