CYLINDER HEAD GASKET INSTALLATION

PROCEDURE

1. INSTALL CYLINDER HEAD GASKET

   
   

   1. Remove any oil from the contact surfaces.

   2. 

      *a	Cylinder Block Sub-assembly
      *b	3.0 to 5.0 mm (0.118 to 0.197 in.)
      *c	10 to 15 mm (0.394 to 0.591 in.)
      *d	Diameter 7.0 to 9.0 mm (0.276 to 0.354 in.)
      	Front of Engine

      Apply seal packing to the cylinder block sub-assembly as shown in the illustration.

      Note

      Install the cylinder head gasket within 3 minutes and tighten the cylinder head set bolts within 15 minutes of applying seal packing.

   3. 

      *a	Lot No.
      	Front of Engine

      Place a new cylinder head gasket on the cylinder block sub-assembly as shown in the illustration.

      Note

      Make sure to install the cylinder head gasket in the correct direction.

   4. 

      *a	Cylinder Head Gasket
      *b	Diameter 6 to 8 mm (0.236 to 0.315 in.)
      	Front of Engine

      Apply seal packing to the cylinder head gasket as shown in the illustration.

2. INSTALL CYLINDER HEAD SUB-ASSEMBLY

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3. INSTALL VALVE STEM CAP

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4. INSTALL VALVE LASH ADJUSTER ASSEMBLY

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

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6. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

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7. INSTALL NO. 2 CAMSHAFT

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8. INSTALL CAMSHAFT

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9. INSTALL CAMSHAFT BEARING CAP

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10. INSTALL CAMSHAFT TIMING SPROCKET

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11. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

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

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13. INSTALL CHAIN SUB-ASSEMBLY

    Tech Tips

    
    

    • Be sure to install the chain sub-assembly with the mark plates facing away from the engine assembly.

    • The mark plate on the camshaft side is colored orange.

    • The mark plate on the crankshaft side is colored pink.

    
    

    1. Temporarily install the crankshaft pulley set bolt to the crankshaft.

    2. 

       Install the No. 1 chain vibration damper to the cylinder head sub-assembly and cylinder block sub-assembly with the 2 bolts.

       Torque:

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

    3. 

       *a	Place the chain sub-assembly on the sprocket
       *b	Pass the chain sub-assembly through the damper
       *c	Mark Plate (Orange)
       *d	Timing Mark (Rectangle)
       *e	Mark (Circle)

       Install the chain sub-assembly with the mark plates (orange) of the chain sub-assembly aligned with the timing mark (rectangle) as shown in the illustration.

       Tech Tips

       
       

       • There are 3 marks on the camshaft timing sprocket. Make sure to align the mark plate with the timing mark (rectangle).

       • Do not pass the chain sub-assembly around the sprocket of the camshaft timing gear assembly. Only place it on the camshaft timing gear assembly.

       • Pass the chain sub-assembly through the No. 1 chain vibration damper.

    4. 

       Place the chain sub-assembly on the crankshaft without passing it around the crankshaft.

    5. Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear assembly counterclockwise to align the mark plate (orange) with timing mark, and then install the chain sub-assembly.

       

       *a	Tension the chain sub-assembly	*b	Mark Plate (Orange)
       *c	Timing Mark	-	-

       Tech Tips

       If the camshaft timing gear assembly cannot be positioned as shown in the illustration, using a wrench to hold the hexagonal portion of the camshaft, slightly rotate the camshaft timing gear assembly counterclockwise and then install the chain sub-assembly.

    6. Using a wrench to hold the hexagonal portion of the camshaft, slowly turn the camshaft timing gear assembly clockwise to tension the chain sub-assembly between the camshaft timing sprocket and camshaft timing gear assembly.

       Tech Tips

       Make sure to turn the camshaft timing gear assembly slowly to prevent the camshaft timing sprocket from becoming misaligned.

    7. 

       *a	Timing Mark
       *b	Mark Plate (Pink)

       Align the mark plate (pink) with timing mark and install the chain sub-assembly to the crankshaft timing sprocket.

    8. Check that each timing mark is at TDC (compression).

       

       *a	Mark Plate (Orange)	*b	Mark Plate (Pink)
       *c	Timing Mark	*d	Timing Mark (Rectangle)
       *e	Mark (Circle)	-	-

       Tech Tips

       There are 3 marks on the camshaft timing sprocket. Make sure that the timing mark (rectangle) is at the top.

    9. Remove the crankshaft pulley set bolt from the crankshaft.

14. INSTALL NO. 2 CHAIN VIBRATION DAMPER

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15. INSTALL CHAIN TENSIONER SLIPPER

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16. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

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17. INSTALL TIMING CHAIN COVER OIL SEAL

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18. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

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19. INSTALL CRANKSHAFT PULLEY

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20. INSTALL SPARK PLUG TUBE GASKET

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21. INSTALL CYLINDER HEAD COVER GASKET

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22. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

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23. INSTALL IGNITION COIL ASSEMBLY

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24. INSTALL FUEL INJECTOR ASSEMBLY

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25. INSTALL NO. 1 DELIVERY PIPE SPACER

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26. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

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27. INSTALL FUEL VAPOR FEED PIPE

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28. INSTALL PURGE VALVE (PURGE VSV)

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29. INSTALL NO. 6 WATER BY-PASS PIPE

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30. INSTALL NO. 5 WATER BY-PASS PIPE (w/ Exhaust Heat Recirculation System)

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31. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

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32. INSTALL ENGINE OIL LEVEL DIPSTICK

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33. INSTALL INTAKE MANIFOLD

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34. INSTALL EXHAUST MANIFOLD (TWC: Front Catalyst)

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35. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

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36. TEMPORARILY INSTALL EGR VALVE ASSEMBLY WITH EGR COOLER

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37. TEMPORARILY INSTALL EGR PIPE ASSEMBLY

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38. INSTALL EGR VALVE ASSEMBLY WITH EGR COOLER

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39. INSTALL EGR PIPE ASSEMBLY

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40. INSTALL WATER OUTLET (w/ Flow Shutting Valve (Water Valve))

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41. INSTALL WATER OUTLET (w/o Flow Shutting Valve (Water Valve))

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42. INSTALL ENGINE HANGERS

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43. REMOVE ENGINE ASSEMBLY FROM ENGINE STAND

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