Thoroughly clean all parts to be assembled.
Always use a new head and manifold gasket.
The cylinder head gasket is a metal gasket. Take care not to bend it.
Rotate the crankshaft, set the No.1 piston at TDC.
Install the cylinder head gasket (A) on the cylinder block.
Be careful of the installation direction.
Apply liquid gasket (Loctite 5900H or equivalent) on the edge of cylinder head gasket upside and downside. (At the position 'B')
After applying sealant, assemble the cylinder head in five minutes.
Place the cylinder head carefully in order not to damage the gasket with the bottom part of the end.
Install cylinder head bolts.
Do not apply engine oil on the the cylinder head bolts.
Using the SST(09221-4A000), tighten the cylinder head bolts and plate washers, in several passes, in the sequence shown.
Tightening torque :
32.4 ~ 36.3 N.m (3.3 ~ 3.7 kgf.m, 23.9 ~ 26.8 lb-ft) + 90 ~ 95° + 90 ~ 95°
Always use new cylinder head bolt.
Install the injector & rail module (A).
Pre-tighten the bolts and then tighten the bolts with the specified torque in the sequence shown.
Tightening torque :
18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)
Install the intake CMPS (Camshaft position sensor) (A).
Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
Install the exhaust CMPS (Camshaft position sensor) (A) and the engine hanger (B).
Tightening torque
Sensor bolt:
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
Engine hanger bolt:
27.5 ~ 31.4 N.m (2.8 ~ 3.2 kgf.m, 20.3 ~ 23.1 lb-ft)
Install the intake OCV (Oil control valve) (A).
Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
Install the exhaust OCV (Oil control valve) (A).
Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
Do not reuse the OCV when dropped.
Keep the OCV filter clean.
Do not hold the OCV sleeve during servicing.
When the OCV is installed on the engine, do not move the engine with holding the OCV yoke.
Install the cmashaft.
Install the exhaust camshaft lower bearing (A).
Install the camshafts (A).
Install the exhaust camshaft upper bearing (A) to the front bearing cap.
Install camshaft bearing caps (A) in their proper locations.
Tightening order
Group A → Group B → Group C.
Tightening torque :
Step 1
M6 : 5.9 N.m (0.6 kgf.m, 4.3 lb-ft)
M8 : 14.7 N.m (1.5 kgf.m, 10.8 lb-ft)
Step 2
M6 : 10.8 ~ 12.7 N.m (1.1 ~ 1.3 kgf.m, 8.0 ~ 9.4 lb-ft)
M8 : 27.5 ~ 31.4 N.m (2.8 ~ 3.2 kgf.m, 20.3 ~ 23.1 lb-ft)
Install the timming chain.
(Refer to Timming System - "Timming Chain")
Install the timming chain cover.
(Refer to Timming System - "Timming Chain Cover")
Install the cylinder head cover.
(Refer to Cylinder Head Assembly - "Cylinder Head Cover")
Install the exhaust manofold.
(Refer to Intake And Exhaust System - "Exhaust Manifold")
Install the intake manofold.
(Refer to Intake And Exhaust System - "Intake Manifold")
