CYLINDER HEAD GASKET INSTALLATION

CAUTION / NOTICE / HINT

PROCEDURE

1. INSTALL CYLINDER HEAD GASKET

   
   

   1. Clean the cylinder block sub-assembly and cylinder head sub-assembly with solvent.

   2. 

      *a	Lot No.
      	Front of Engine

      Place a new cylinder head gasket on the cylinder block sub-assembly with the Lot No. stamp facing upward.

      Note

      Make sure that the cylinder head gasket is installed in the correct orientation.

2. INSTALL CYLINDER HEAD SUB-ASSEMBLY

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3. INSTALL NO. 2 CAMSHAFT

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4. INSTALL CAMSHAFT

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5. INSTALL CAMSHAFT BEARING CAP

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6. INSTALL VALVE STEM CAP

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7. INSTALL VALVE LASH ADJUSTER ASSEMBLY

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8. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

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9. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

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10. INSTALL FUEL PUMP LIFTER GUIDE

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11. INSTALL TIMING CHAIN COVER ASSEMBLY

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12. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

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13. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

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14. SET NO. 1 CYLINDER TO TDC (COMPRESSION)

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15. INSTALL NO. 1 CHAIN VIBRATION DAMPER

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16. INSTALL CHAIN SUB-ASSEMBLY

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17. INSTALL CHAIN TENSIONER SLIPPER

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18. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

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19. INSTALL OIL PUMP DRIVE CHAIN SUB-ASSEMBLY

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20. SET NO. 1 CYLINDER TO TDC (COMPRESSION)

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21. INSTALL NO. 2 TIMING GEAR COVER ASSEMBLY

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22. INSTALL TIMING CHAIN COVER OIL SEAL

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23. INSTALL SPARK PLUG TUBE GASKET

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24. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

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25. INSTALL OUTLET WATER BY-PASS SUB-ASSEMBLY

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26. INSTALL WATER OUTLET

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27. INSTALL CRANKSHAFT PULLEY ASSEMBLY

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28. INSTALL VACUUM PUMP ASSEMBLY

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29. CONNECT NO. 2 WATER BY-PASS HOSE (w/ Oil Cooler)

    
    

    1. Connect the No. 2 water by-pass hose to the water by-pass pipe sub-assembly and slide the clip to secure it.

30. CONNECT NO. 1 WATER BY-PASS HOSE (w/ Oil Cooler)

    
    

    1. Connect the No. 1 water by-pass hose to the cylinder block sub-assembly and slide the clip to secure it.

31. INSTALL CAM TIMING CONTROL MOTOR O-RING

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32. INSTALL CAM TIMING CONTROL MOTOR WITH EDU ASSEMBLY

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33. INSTALL CAM TIMING OIL CONTROL SOLENOID ASSEMBLY

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34. INSTALL OIL PRESSURE CONTROL VALVE ASSEMBLY

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35. INSTALL PURGE VALVE (PURGE VSV)

    
    

    • w/ Canister Pump Module:

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    • w/o Canister Pump Module:

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36. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

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37. INSTALL IGNITION COIL ASSEMBLY

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38. INSTALL FUEL INJECTOR SEAL

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39. INSTALL DIRECT FUEL INJECTOR ASSEMBLY

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40. INSTALL FUEL DELIVERY PIPE

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41. INSTALL PORT FUEL INJECTOR ASSEMBLY

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42. INSTALL NO. 5 ENGINE WIRE

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43. INSTALL INJECTOR VIBRATION INSULATOR

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44. INSTALL NO. 1 DELIVERY PIPE SPACER

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45. INSTALL FUEL DELIVERY PIPE WITH SENSOR ASSEMBLY

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46. INSTALL NO. 7 WATER BY-PASS HOSE

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47. TEMPORARILY INSTALL FUEL PUMP ASSEMBLY (for High Pressure)

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48. TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

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49. INSTALL FUEL PUMP ASSEMBLY (for High Pressure)

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50. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

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51. CONNECT FUEL TUBE SUB-ASSEMBLY

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52. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET

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53. INSTALL INTAKE MANIFOLD

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54. INSTALL NO. 2 WATER BY-PASS PIPE

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55. INSTALL NO. 3 WATER BY-PASS PIPE

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56. INSTALL EGR VALVE ASSEMBLY

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57. INSTALL WATER HOSE CONNECTOR

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58. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY

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59. INSTALL NO. 1 EGR COOLER BRACKET

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60. INSTALL EGR COOLER ASSEMBLY

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61. INSTALL THROTTLE BODY GASKET

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62. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

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63. INSTALL EXHAUST MANIFOLD (TWC: Front Catalyst)

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64. INSTALL MANIFOLD STAY

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65. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

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66. INSTALL FLOW SHUTTING VALVE (WATER BY-PASS HOSE ASSEMBLY)

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67. INSTALL NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY

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68. INSTALL NO. 3 TIMING CHAIN COVER

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69. INSTALL TIMING GEAR COVER INSULATOR

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70. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

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71. INSTALL NO. 2 ENGINE COVER

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72. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY

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73. INSTALL GENERATOR ASSEMBLY

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74. INSTALL V-RIBBED BELT

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75. INSTALL ENGINE HANGERS

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76. REMOVE ENGINE ASSEMBLY FROM ENGINE STAND

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