## Cylinder Head Installation

Install the cylinder head in the reverse order of removal:

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.

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.

7. | Tighten all cylinder head bolts an additional 130°.

8. | Install the cam chain guide mounting bolt.

9. | Install the cam chain to the camshaft sprocket by alignment the reference mark (A), then install the camshaft sprocket on the camshaft.

10. | Hold the camshaft with an open-end wrench, then tighten the bolt.
Specified torque:
56 N·m (5.7 kgf·m, 41 lbf·ft)

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.

13. | Hold the crankshaft pulley and set the socket wrench (A) on the camshaft sprocket bolt.

14. | Turn the camshaft clockwise to compress the cam chain tensioner, then remove the 6 x 1.0 mm bolt (B) NOTE: Turning torque should not exceed 56 N·m (5.7 kgf·m, 41 lbf·ft), when turning the camshaft. Do not turn the camshaft counterclockwise.

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: Apply a 1.5 mm wide bead of the liquid gasket along the broken line (A). Apply a 3.0 mm wide bead of the liquid gasket to the cylinder block upper surface contact areas (B) on the chain case.

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: Apply a 1.5 mm wide bead of the liquid gasket along the broken line (A). Apply a 5.0 mm wide bead of the liquid gasket to the shaded area (B). Do not install the parts if 5 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing old residue.

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.

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).

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).

32. | Install the fuel rail, refer to the 2002 Jazz/Fit Shop Manua.

33. | Install the exhaust manifold.

34. | Install the intake manifold.

35. | Install the heater hoses.

36. | Install the upper radiator hose (A) and lower radiator hose (B).

37. | Install the water bypass hoses.

38. | Install air cleaner housing, refer to the 2002 Jazz/Fit Shop Manua.

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.