CYLINDER HEAD GASKET INSTALLATION


  1. INSTALL CYLINDER HEAD GASKET


    1. A01CCMVE03
      Text in Illustration
      *1 Lot No.

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

      Note


      • Remove any oil from the contact surfaces.

      • Be careful of the installation direction.

  2. INSTALL CYLINDER HEAD SUB-ASSEMBLY


    1. Place the cylinder head on the cylinder head gasket.

      Note

      Place the cylinder head gently in order to avoid damaging the cylinder head gasket.

    2. Install the cylinder head bolts.

      Note

      The cylinder head bolts are tightened in 2 successive steps.


      1. A01CBVRE03

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

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

        Torque:
        70 N*m  { 714 kgf*cm, 52 ft.*lbf }
    3. A01CDINE05
      Text in Illustration
      *1 Paint Mark
      A01CCA7 Engine Front

      Mark the front of the cylinder head bolts with paint.

    4. Further tighten the cylinder head bolts 90° as shown in the illustration.

    5. Check that the paint mark is now at a 90° angle to the front.

  3. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY


    1. Install a new exhaust manifold to head gasket.

    2. A01CDXGE02

      Using a 12 mm deep socket wrench, install the exhaust manifold converter sub-assembly and 5 nuts in the order shown in the illustration.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

  4. INSTALL NO. 2 MANIFOLD STAY


    1. Install the No. 2 manifold stay with the bolt and nut.

      Torque:
      44 N*m  { 449 kgf*cm, 33 ft.*lbf }

  5. INSTALL MANIFOLD STAY


    1. Install the manifold stay with the bolt and nut.

      Torque:
      44 N*m  { 449 kgf*cm, 33 ft.*lbf }

  6. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. Install the No. 1 exhaust manifold heat insulator with the 4 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  7. INSTALL INTAKE MANIFOLD


    1. Install the vacuum hose clamp with the bolt.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

    2. Install the union to check valve hose, No. 2 ventilation hose and No. 1 throttle body hose.

    3. Install the No. 1 intake manifold insulator.

    4. Install a new No. 1 intake manifold to head gasket.

    5. Set the intake manifold.

    6. Connect the engine wire.


      1. A01CF25

        Connect the engine wire harness with the 2 bolts.

      2. A01CATI

        Connect the connector and wire harness clamp.

      3. A01CBF3

        Install the earth bolt.

        Torque:
        8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

      4. Connect the 4 connectors.

      5. A01CD02

        Connect the 4 connectors.

      6. A01CD1G

        Install the earth bolt.

        Torque:
        8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

      7. Connect the connector and 3 wire harness clamps.

      8. A01CAQ1

        Connect the earth connector and wire harness clamp.

      9. A01CGIS

        Connect the terminal B with the nut and install the terminal cap.

        Torque:
        9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

      10. Connect the 2 connectors and 2 wire harness clamps.

      11. A01CBKV

        Connect the compressor connector and clamp.

    7. Using an E7 "TORX" wrench, install the 2 stud bolts.

      Torque:
      9.5 N*m  { 97 kgf*cm, 84 in.*lbf }

    8. Install the intake manifold with the 5 bolts and 2 nuts.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

    9. Connect the union to check valve hose to the hose clamp.

    10. Connect the oxygen sensor connector and clamp.

  8. INSTALL THROTTLE BODY ASSEMBLY


    1. A01CD9V

      Install a new gasket onto the intake manifold.

    2. A01CAZR

      Temporarily install the throttle body assembly and fuel pipe support bracket with the 3 bolts.

    3. A01CEV1E01

      Connect the 2 water by-pass hoses. (*1).

    4. Connect the purge line hose. (*2)

    5. Connect the No. 1 throttle body hose. (*3)

    6. A01CCON

      Install the fuel pipe support bracket and throttle body assembly with the 4 bolts.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }
    7. A01CB1V

      Connect the throttle body connector to the throttle body assembly.

    8. Connect the wire harness clamp to the fuel pipe support bracket.

    9. Install the hose to the fuel pipe support bracket.

  9. INSTALL NO. 1 CAMSHAFT BEARING


    1. Clean the installation surfaces of the cap and the inner and outer surfaces of the bearing.

      Note

      Keep the installation surfaces and the back surfaces of the bearing free of engine oil.

    2. A01CAPVE06
      Text in Illustration
      *a Claw

      Align the claws and install the No. 1 camshaft bearing onto the No. 1 camshaft bearing cap.

  10. INSTALL NO. 2 CAMSHAFT BEARING


    1. Clean the installation surfaces of the cap and the inner and outer surfaces of the bearing.

      Note

      Keep the installation surfaces and the back surfaces of the bearing free of engine oil.

    2. A01CG0NE01

      Install the No. 2 camshaft bearing onto the cylinder head.

  11. INSTALL CAMSHAFT


    1. Apply a light coat of engine oil to the journal portion.

    2. A01CG2H

      Place the camshaft on the cylinder head with the No. 1 cam lobes facing the directions shown in the illustration.

    3. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

    4. A01CF42E03

      Examine the front marks and numbers, and check that the order is as shown in the illustration. Then install the bearing caps into the cylinder head.

    5. A01CF42E10
      Text in Illustration
      *a No. 1

      Using several steps, uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration.

      Torque:
      No. 1 Bearing cap
      30 N*m  { 301 kgf*cm, 22 ft.*lbf }
      No. 3 Bearing cap
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  12. INSTALL NO. 2 CAMSHAFT


    1. Apply a light coat of engine oil to the journal portion of the No. 2 camshaft.

    2. A01CGGB

      Place the camshaft on the cylinder head with the No. 2 cam lobes facing the directions shown in the illustration.

    3. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

    4. A01CEB0E05

      Examine the front marks and numbers, and check that the order is as shown in the illustration. Then install the bearing caps onto the cylinder head.

    5. A01CEB0E14
      Text in Illustration
      *a No. 2

      Using several steps, uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration.

      Torque:
      No. 2 Bearing cap
      30 N*m  { 301 kgf*cm, 22 ft.*lbf }
      No. 3 Bearing cap
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  13. CONNECT ENGINE WIRE


    1. A01CF8UE01

      Connect the ground cable with the bolt.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

    2. Connect the camshaft position sensor connector.

    3. Connect the engine coolant temperature sensor connector.

    4. Connect the engine oil pressure switch connector.

    5. Connect the radio setting condenser connector.

    6. Connect the heater water inlet hose.

  14. INSTALL NO. 1 CHAIN VIBRATION DAMPER


    1. A01CF5G

      Install the No. 1 chain vibration damper with the 2 bolts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  15. INSTALL CHAIN SUB-ASSEMBLY


    1. Set the No. 1 cylinder to TDC/compression.


      1. A01CEAGE02
        Text in Illustration
        *1 Timing Mark

        Turn the camshafts with a wrench (using the hexagonal lobe) to align the timing marks on the camshaft timing gear with the timing marks located on the No. 1 and No. 2 bearing caps as shown in the illustration.

      2. A01CFKIE01

        Using the crankshaft pulley bolt, turn the crankshaft to position the key on the crankshaft upward.

    2. A01CCHVE05
      Text in Illustration
      *1 Timing Mark
      *2 Mark Link

      Install the chain onto the crankshaft timing sprocket with the gold or orange mark link aligned with the timing mark on the crankshaft.

    3. A01CEW2E01

      Using SST and a hammer, tap in the crankshaft timing sprocket.

      SST
      09309-37010
    4. A01CDZKE04
      Text in Illustration
      *1 Mark Link
      *2 Timing Mark

      Align the gold or yellow links with the timing marks located on the camshaft timing gear and sprocket, then install the chain.

  16. INSTALL CHAIN TENSIONER SLIPPER


    1. A01CAWPE05
      Text in Illustration
      *a Hold

      Install the chain tensioner slipper with the bolt.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

  17. INSTALL TIMING CHAIN GUIDE


    1. A01CFN4E01

      Install the timing chain guide with the bolt.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  18. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. A01CFA0

      Install the sensor plate with the "F" mark facing forward.

  19. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY

    Tech Tips

    See the steps from "Install Timing Chain or Belt Cover Sub-Assembly" through "Install Continuously Variable Transaxle Assembly" Click here.