CYLINDER HEAD GASKET INSTALLATION

CAUTION / NOTICE / HINT

Tech Tips

Perform "Inspection After Repairs" after replacing the cylinder head sub-assembly or cylinder head LH.


PROCEDURE


  1. INSPECT CYLINDER HEAD SET BOLT

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  2. INSTALL CYLINDER HEAD GASKET


    1. B000VUTC01
      *a Lot No.
      B000TT4 Engine Front

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

      Note


      • Be sure to place the gasket in the correct orientation.

      • Gently lower the cylinder head sub-assembly in order not to damage the cylinder head gasket with the bottom of the cylinder head sub-assembly.

  3. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Tech Tips

    Perform "Inspection After Repairs" after replacing the cylinder head sub-assembly.



    1. Place the cylinder head sub-assembly on the cylinder block sub-assembly.

      Note


      • Clean all contact surfaces.

      • Inspect and clean each cylinder head set bolt and bolt hole.

      • Gently place the cylinder head sub-assembly in order not to damage the cylinder head gasket with the bottom part of the cylinder head sub-assembly.

    2. Apply a light coat of engine oil to the threads and under the heads of the cylinder head set bolts.

      Tech Tips

      The cylinder head set bolts are tightened in 3 progressive steps.

    3. Step 1:


      1. B000Y5XN06

        Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 10 cylinder head set bolts with the plate washers in several steps in the order shown in the illustration.

        Torque:
        36 N*m  { 367 kgf*cm, 27 ft.*lbf }

    4. Step 2:


      1. B000XBAC02
        *a Paint Mark
        *b 90°
        B000TT4 Engine Front

        Mark each cylinder head set bolt head with paint as shown in the illustration.

      2. Tighten the cylinder head set bolts another 90° in the order shown in step 1.

    5. Step 3:


      1. Tighten the cylinder head set bolts by an additional 90° in the order shown in step 1.

      2. Check that the paint marks are now facing rearward.

    6. B000VQFN05

      Install the 2 cylinder head set bolts in the order shown in the illustration.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    7. Place the camshaft housing RH on the cylinder head sub-assembly.

    8. B000Z5MN01

      Temporarily tighten the 3 bolts in the order shown in the illustration.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    9. Fully tighten the 3 bolts in the order shown in the illustration.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

  4. INSTALL NO. 2 CYLINDER HEAD GASKET


    1. B000UJXC01
      *a Lot No.
      B000TT4 Engine Front

      Place a new No. 2 cylinder head gasket on the cylinder block sub-assembly with the Lot No. stamp facing upward.

      Note


      • Be sure to place the gasket in the correct orientation.

      • Gently place the cylinder head LH in order not to damage the No. 2 cylinder head gasket with the bottom of the cylinder head LH.

  5. INSTALL CYLINDER HEAD LH

    Tech Tips

    Perform "Inspection After Repairs" after replacing the cylinder head LH.



    1. Place the cylinder head LH on the cylinder block sub-assembly.

      Note


      • Clean all contact surfaces.

      • Inspect and clean each cylinder head set bolt and bolt hole.

      • Gently place the cylinder head LH in order not to damage the No. 2 cylinder head gasket with the bottom part of the cylinder head LH.

    2. Apply a light coat of engine oil to the threads and under the heads of the cylinder head set bolts.

      Tech Tips

      The cylinder head set bolts are tightened in 3 progressive steps.

    3. B000YAXN09

      Step 1:


      1. Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 10 cylinder head set bolts with the 10 plate washers in several steps in the order shown in the illustration.

        Torque:
        36 N*m  { 367 kgf*cm, 27 ft.*lbf }

    4. Step 2:


      1. B000XBAC02
        *a Paint Mark
        *b 90°
        B000TT4 Engine Front

        Mark each cylinder head set bolt head with paint as shown in the illustration.

      2. Tighten the cylinder head set bolts another 90° in the order shown in step 1.

    5. Step 3:


      1. Tighten the cylinder head set bolts by an additional 90° in the order shown in step 1.

      2. Check that the paint marks are now facing rearward.

    6. B000YEXN04

      Install the 2 cylinder head set bolts in the order shown in the illustration.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    7. Place the camshaft housing LH on the cylinder head LH.

    8. B000W9TN01

      Temporarily tighten the 3 bolts in the order shown in the illustration.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    9. Fully tighten the 3 bolts in the order shown in the illustration.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

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

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  7. INSTALL CAMSHAFT

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  8. INSTALL NO. 2 CAMSHAFT

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  9. INSTALL CAMSHAFT BEARING CAP (for Bank 2)

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  10. INSTALL OIL REFLECTOR PLATE RH

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  11. INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY

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  12. INSTALL NO. 4 CAMSHAFT SUB-ASSEMBLY

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  13. INSTALL CAMSHAFT BEARING CAP (for Bank 1)

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  14. INSTALL OIL REFLECTOR PLATE LH

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  15. INSTALL DIRECT FUEL INJECTOR ASSEMBLY

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  16. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH

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  17. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH

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  18. INSTALL ENGINE WITH TRANSMISSION ASSEMBLY

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