CYLINDER HEAD GASKET INSTALLATION


  1. INSTALL CYLINDER HEAD GASKET


    1. A01EWMAE01
      Text in Illustration
      *a 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

    Tech Tips

    The cylinder head set bolts are tightened in 2 progressive steps.


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

      Note

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

    2. Apply a light coat of engine oil to the threads and under the heads of the 10 cylinder head set bolts.

    3. Set the 10 plate washers and 10 cylinder head set bolts.

    4. Step 1:


      1. A01EUV2E02

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

        Torque:
        70 N*m  { 714 kgf*cm, 51 ft.*lbf }

    5. Step 2:


      1. A01EWDSE08
        Text in Illustration
        *a Paint Mark
        A01ETOA Engine Front

        Mark the front of the cylinder head set bolts with paint.

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

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

  3. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY


    1. Set a new gasket to the cylinder head sub-assembly.

    2. Temporarily install the exhaust manifold converter sub-assembly with the 5 nuts.

    3. Temporarily install the No. 2 manifold stay and manifold stay with the 2 bolts and 2 nuts.

    4. A01EVVIE05

      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 }

    5. Connect the air fuel ratio sensor connector.

  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, 32 ft.*lbf }

  5. INSTALL MANIFOLD STAY


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

      Torque:
      44 N*m  { 449 kgf*cm, 32 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 NO. 1 INTAKE MANIFOLD INSULATOR


    1. Install the No. 1 intake manifold insulator to the cylinder block.

  8. INSTALL INTAKE MANIFOLD


    1. Install the vacuum hose clamp with the bolt.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

    2. Install a new No. 1 intake manifold to head gasket to the intake manifold.

    3. Set the intake manifold on the engine assembly.

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

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

    5. Temporarily install the intake manifold with the 5 bolts and 2 nuts.

    6. A01EVP6E03

      Tighten the 5 bolts and 2 nuts in the order shown in the illustration.

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

    7. Connect the oxygen sensor connector and 2 wire harness clamps.

  9. INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY


    1. A01EV9GE01
      Text in Illustration
      *a Groove
      *b Protrusion

      Install a new gasket to the intake manifold.

      Tech Tips

      Align the protrusion of the gasket with the groove on the intake manifold.

    2. Temporarily install the throttle with motor body assembly and fuel tube bracket with the 4 bolts.

    3. Connect the 2 water by-pass hoses.

    4. Connect the purge line hose.

    5. A01EYZD

      Install the fuel tube bracket and the throttle with motor body assembly with the 4 bolts.

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

    6. Connect the throttle with motor body assembly connector to the throttle with motor body assembly.

    7. Connect the wire harness clamp to the fuel tube bracket.

    8. Install the fuel tube to the fuel tube bracket.

  10. CONNECT ENGINE WIRE


    1. Connect the 4 connectors.

    2. Connect the earth wire with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 72 in.*lbf }

  11. INSTALL CAMSHAFT


    1. Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps.

    2. Install the No. 1 camshaft bearing and No. 2 camshaft bearing.

    3. A01EV6S

      Examine the front marks and numbers, and check that the order is as shown in the illustration. Then temporarily install the camshaft and 5 camshaft bearing caps with the 10 bolts.

    4. A01EXRHE02
      Text in Illustration
      *1 No. 1 Camshaft Bearing Cap
      *2 No. 3 Camshaft Bearing Cap

      Using several steps, uniformly tighten the 10 bolts in the order shown in the illustration.

      Torque:
      No. 1 camshaft bearing cap
      30 N*m  { 301 kgf*cm, 22 ft.*lbf }
      No. 3 camshaft 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 camshaft journals, camshaft housings and bearing caps.

    2. A01ET81

      Examine the front marks and numbers, and check that the order is as shown in the illustration. Then temporarily install the No. 2 camshaft and 5 camshaft bearing caps with the 10 bolts.

    3. A01EWFLE02
      Text in Illustration
      *1 No. 2 Camshaft Bearing Cap
      *2 No. 3 Camshaft Bearing Cap

      Using several steps, uniformly tighten the 10 bolts in the order shown in the illustration.

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

  13. INSTALL NO. 1 CHAIN VIBRATION DAMPER


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

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

  14. INSTALL CHAIN SUB-ASSEMBLY


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


      1. A01EWGNE01
        Text in Illustration
        *a Timing Mark
        *b Front Mark

        Using the hexagonal portion of the camshafts, rotate the camshafts with a wrench, align the timing marks on the camshaft timing gear assembly and camshaft timing sprocket with the front marks located on the No. 1 camshaft bearing cap and No. 2 camshaft bearing cap as shown in the illustration.

      2. A01EYTFE02
        Text in Illustration
        *1 Crankshaft Key
        A01EUL1 Up

        Check that the crankshaft is positioned with the crankshaft key facing up as shown in the illustration.

    2. A01EWD4E08
      Text in Illustration
      *1 Mark Link
      *a Timing Mark

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

    3. A01EVKRE01

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

      SST
      09309-37010
    4. A01EUYUE07
      Text in Illustration
      *1 Mark Link
      *a Timing Mark

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

  15. INSTALL CHAIN TENSIONER SLIPPER


    1. Install the chain tensioner slipper with the bolt.

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

  16. INSTALL TIMING CHAIN GUIDE


    1. Install the timing chain guide with the bolt.

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

  17. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. A01EUEJ

      Install the No. 1 crankshaft position sensor plate with the "F" mark facing forward.

  18. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

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