This procedure includes the installation of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.
| Procedure | Part Name Code |
|
|
|
|
|---|---|---|---|---|---|
| 1 | CYLINDER HEAD GASKET | 11115 | ( 202307,999999,_51,_144958,_0604259,RM100000002BTSS_01_0001,)
|
- | - |
| 2 | CYLINDER HEAD SUB-ASSEMBLY | 11101 | ( 202307,999999,_51,_144958,_0604259,RM100000002BTSS_01_0002,)
|
- | - |
| 3 | EXHAUST CAMSHAFT SUB-ASSEMBLY | 13502B | ( 202307,999999,_51,_144958,_0604259,RM100000002BTSS_01_0110,)
|
- | - |
| 4 | INTAKE CAMSHAFT SUB-ASSEMBLY | 13501A | ( 202307,999999,_51,_144958,_0604259,RM100000002BTSS_01_0111,)
|
- | - |
| 5 | CAMSHAFT BEARING CAP | - | ( 202307,999999,_51,_144958,_0604259,RM100000002BTSS_01_0112,)
|
- | - |
| 6 | VALVE LASH ADJUSTER ASSEMBLY | 13750 | ( 202307,999999,_51,_144958,_0604259,RM100000002BTSS_01_0081,)
|
- | - |
| 7 | NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY | 13801 | ( 202307,999999,_51,_144958,_0604259,RM100000002BTSS_01_0082,)
|
- | - |
| 8 | CAMSHAFT HOUSING SUB-ASSEMBLY | 11103 | ( 202307,999999,_51,_144958,_0604259,RM100000002BTSS_01_0083,)
|
- | - |
| 9 | FUEL PUMP LIFTER GUIDE | 23477 | ( 202307,999999,_51,_144958,_0604259,RM100000002BTSS_01_0084,)
|
- | - |
|
Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf) |
|
N*m (kgf*cm, ft.*lbf): Specified torque |
| ● | Non-reusable part | - | - |
| *T1 | 1st: 50 (510, 37)
2nd: Turn 90° 3rd: Turn 90° |
- | - |
|
Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf) |
|
N*m (kgf*cm, ft.*lbf): Specified torque |
| ● | Non-reusable part |
|
MP grease |
|
Do not apply lubricants to the threaded parts | - | - |
| Procedure | Part Name Code |
|
|
|
|
|---|---|---|---|---|---|
| 22 | SPARK PLUG TUBE GASKET | 11193 | - | - | - |
| 23 | CYLINDER HEAD COVER SUB-ASSEMBLY | 11201 | ( 202307,999999,_51,_144958,_0604259,RM100000002BTSS_01_0096,)
|
- | - |
|
N*m (kgf*cm, ft.*lbf): Specified torque | ● | Non-reusable part |
| ★ | Precoated part | - | - |
| Procedure | Part Name Code |
|
|
|
|
|---|---|---|---|---|---|
| 24 | WATER BY-PASS OUTLET | 16351 | ( 202307,999999,_51,_144958,_0604259,RM100000002BTSS_01_0097,)
|
- | - |
| 25 | WATER OUTLET SUB-ASSEMBLY | 16304 | - | - | - |
| 26 | CRANKSHAFT PULLEY ASSEMBLY | 13470 | ( 202307,999999,_51,_144958,_0604259,RM100000002BTSS_01_0100,)
|
- | - |
| 27 | CAM TIMING CONTROL MOTOR O-RING | 13090E | ( 202307,999999,_51,_144958,_0604259,RM100000002BTSS_01_0103,)
|
- | - |
| 28 | CAM TIMING CONTROL MOTOR WITH EDU ASSEMBLY | 13090D | ( 202307,999999,_51,_144958,_0604259,RM100000002BTSS_01_0104,)
|
- | - |
| 29 | O-RING | - | ( 202307,999999,_51,_144958,_0604259,RM100000002BTSS_01_0168,)
|
- | - |
| 30 | CAM TIMING OIL CONTROL SOLENOID ASSEMBLY | 15370 | ( 202307,999999,_51,_144958,_0604259,RM100000002BTSS_01_0076,)
|
- | - |
| 31 | CAMSHAFT POSITION SENSOR (for Exhaust Side) | 11102A | ( 202307,999999,_51,_144958,_0604259,RM100000002BTSS_01_0176,)
|
- | - |
| 32 | CAMSHAFT POSITION SENSOR (for Intake Side) | 11102A | ( 202307,999999,_51,_144958,_0604259,RM100000002BTSS_01_0175,)
|
- | - |
| 33 | OIL PRESSURE CONTROL VALVE ASSEMBLY | 15250 | ( 202307,999999,_51,_144958,_0604259,RM100000002BTSS_01_0077,)
|
- | - |
| 34 | ENGINE OIL LEVEL DIPSTICK GUIDE | 11452D | - | - | - |
| 35 | IGNITION COIL ASSEMBLY | 19500 | ( 202307,999999,_51,_144958,_0604259,RM100000002BTSS_01_0124,)
|
- | - |
|
Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf) |
|
N*m (kgf*cm, ft.*lbf): Specified torque |
| ● | Non-reusable part | ★ | Precoated part |
| Procedure | Part Name Code |
|
|
|
|
|---|---|---|---|---|---|
| 36 | FUEL INJECTOR SEAL | 23255A | ( 202307,999999,_51,_144958,_0604259,RM100000002BTSS_01_0156,)
|
- | - |
| 37 | INJECTOR VIBRATION INSULATOR | 23291A | ( 202307,999999,_51,_144958,_0604259,RM100000002BTSS_01_0174,)
|
- | - |
| 38 | C-RING | - | ( 202307,999999,_51,_144958,_0604259,RM100000002BTSS_01_0173,)
|
- | - |
| 39 | NO. 1 FUEL INJECTOR BACK-UP RING | 23256 | ( 202307,999999,_51,_144958,_0604259,RM100000002BTSS_01_0172,)
|
- | - |
| 40 | NO. 3 FUEL INJECTOR BACK-UP RING | 23258 | ( 202307,999999,_51,_144958,_0604259,RM100000002BTSS_01_0171,)
|
- | - |
| 41 | NOZZLE HOLDER CLAMP | 23695A | - | - | - |
| 42 | DIRECT FUEL INJECTOR ASSEMBLY | 23250E | ( 202307,999999,_51,_144958,_0604259,RM100000002BTSS_01_0127,)
|
- | - |
| 43 | FUEL DELIVERY PIPE | 23814B | ( 202307,999999,_51,_144958,_0604259,RM100000002BTSS_01_0128,)
|
- | - |
| 44 | PORT FUEL INJECTOR ASSEMBLY | 23250F | ( 202307,999999,_51,_144958,_0604259,RM100000002BTSS_01_0125,)
|
- | - |
| 45 | NO. 5 ENGINE WIRE | 82125N | - | - | - |
| 46 | INJECTOR VIBRATION INSULATOR | 23291 | - | - | - |
| 47 | FUEL DELIVERY SPACER | 23891 | - | - | - |
| 48 | FUEL DELIVERY PIPE SUB-ASSEMBLY | 23807 | ( 202307,999999,_51,_144958,_0604259,RM100000002BTSS_01_0126,)
|
- | - |
| 49 | WATER BY-PASS HOSE ASSEMBLY | - | - | - | - |
| 50 | FUEL PUMP LIFTER ASSEMBLY | 23470 | ( 202307,999999,_51,_144958,_0604259,RM100000002BTSS_01_0169,)
|
- | - |
| 51 | FUEL PUMP SPACER GASKET | 23224D | - | - | - |
| 52 | FUEL PUMP FLANGE | 23191 | - | - | - |
| 53 | TEMPORARILY INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure) | 23100X | ( 202307,999999,_51,_144958,_0604259,RM100000002BTSS_01_0147,)
|
- | - |
| 54 | TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY | 23801P | ( 202307,999999,_51,_144958,_0604259,RM100000002BTSS_01_0148,)
|
- | - |
| 55 | FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure) | 23100X | ( 202307,999999,_51,_144958,_0604259,RM100000002BTSS_01_0130,)
|
- | - |
| 56 | NO. 1 FUEL PIPE SUB-ASSEMBLY | 23801P | ( 202307,999999,_51,_144958,_0604259,RM100000002BTSS_01_0131,)
|
- | - |
| 57 | CONNECT FUEL TUBE SUB-ASSEMBLY | 23910A | ( 202307,999999,_51,_144958,_0604259,RM100000002BTSS_01_0153,)
|
- | - |
|
Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf) |
|
N*m (kgf*cm, ft.*lbf): Specified torque |
| * | For use with a union nut wrench | ● | Non-reusable part |
| Procedure | Part Name Code |
|
|
|
|
|---|---|---|---|---|---|
| 58 | NO. 1 INTAKE MANIFOLD TO HEAD GASKET | 17177 | - | - | - |
| 59 | INTAKE MANIFOLD | 17111 | ( 202307,999999,_51,_144958,_0604259,RM100000002BTSS_01_0132,)
|
- | - |
| 60 | INTAKE MANIFOLD STAY | 17138B | ( 202307,999999,_51,_144958,_0604259,RM100000002BTSS_01_0161,)
|
- | - |
| 61 | NO. 3 WATER BY-PASS PIPE | 16279 | ( 202307,999999,_51,_144958,_0604259,RM100000002BTSS_01_0134,)
|
- | - |
| 62 | EGR VALVE ASSEMBLY | 25620 | ( 202307,999999,_51,_144958,_0604259,RM100000002BTSS_01_0135,)
|
- | - |
| 63 | CONNECT NO. 8 WATER BY-PASS HOSE | 16296 | - | - | - |
| 64 | CONNECT NO. 4 WATER BY-PASS HOSE | 16281 | - | - | - |
| 65 | EGR INLET GASKET | 25628 | - | - | - |
| 66 | EGR VALVE ADAPTER GASKET | 25629 | - | - | - |
| 67 | NO. 1 EGR PIPE SUB-ASSEMBLY | 25601 | ( 202307,999999,_51,_144958,_0604259,RM100000002BTSS_01_0136,)
|
- | - |
| 68 | NO. 1 EGR COOLER GASKET | 25685 | ( 202307,999999,_51,_144958,_0604259,RM100000002BTSS_01_0182,)
|
- | - |
| 69 | EGR VALVE GASKET | 25627 | ( 202307,999999,_51,_144958,_0604259,RM100000002BTSS_01_0181,)
|
- | - |
| 70 | EGR COOLER ASSEMBLY | 25680 | ( 202307,999999,_51,_144958,_0604259,RM100000002BTSS_01_0138,)
|
- | - |
| 71 | CONNECT NO. 4 WATER BY-PASS HOSE | 16281 | - | - | - |
| 72 | CONNECT NO. 3 WATER BY-PASS HOSE | 16267 | - | - | - |
| 73 | THROTTLE BODY GASKET | 22271 | ( 202307,999999,_51,_144958,_0604259,RM100000002BTSS_01_0139,)
|
- | - |
| 74 | THROTTLE BODY WITH MOTOR ASSEMBLY | 22030 | ( 202307,999999,_51,_144958,_0604259,RM100000002BTSS_01_0140,)
|
- | - |
| *a | x2 or x3 | *b | x3 or x2 |
|
N*m (kgf*cm, ft.*lbf): Specified torque | ● | Non-reusable part |
| Procedure | Part Name Code |
|
|
|
|
|---|---|---|---|---|---|
| 75 | EXHAUST MANIFOLD | 17141 | ( 202307,999999,_51,_144958,_0604259,RM100000002BTSS_01_0141,)
|
- | - |
| 76 | MANIFOLD STAY | 17118 | - | - | - |
| 77 | NO. 1 EXHAUST MANIFOLD HEAT INSULATOR | 17167 | - | - | - |
| 78 | BRACKET | 23211K | - | - | - |
| 79 | NO. 1 VACUUM PIPE | 25733A | ( 202307,999999,_51,_144958,_0604259,RM100000002BTSS_01_0167,)
|
- | - |
| 80 | ENGINE HANGERS | - | - | - | - |
| 81 | REMOVE ENGINE ASSEMBLY FROM ENGINE STAND | - | ( 202307,999999,_51,_144958,_0604259,RM100000002BTSS_01_0080,)
|
- | - |
|
N*m (kgf*cm, ft.*lbf): Specified torque | * | For use with a union nut wrench |
| ● | Non-reusable part | - | - |
11115
1.INSTALL CYLINDER HEAD GASKET
| *a | Lot No. | - | - |
|
Front of Engine | - | - |
Clean the cylinder block sub-assembly and cylinder head sub-assembly with solvent.
Place a new cylinder head gasket on the cylinder block sub-assembly as shown in the illustration.
Make sure that the cylinder head gasket is installed in the correct orientation.
11101
2.INSTALL CYLINDER HEAD SUB-ASSEMBLY
13502B
3.INSTALL EXHAUST CAMSHAFT SUB-ASSEMBLY
13501A
4.INSTALL INTAKE CAMSHAFT SUB-ASSEMBLY
5.INSTALL CAMSHAFT BEARING CAP
13750
6.INSTALL VALVE LASH ADJUSTER ASSEMBLY
13801
7.INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
11103
8.INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY
23477
9.INSTALL FUEL PUMP LIFTER GUIDE
11310
10.INSTALL TIMING CHAIN COVER ASSEMBLY
13070A
11.INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY
12.SET NO. 1 CYLINDER TO TDC (COMPRESSION)
13561
13.INSTALL NO. 1 CHAIN VIBRATION DAMPER
13559
14.INSTALL CHAIN TENSIONER SLIPPER
13540
15.INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
13506
16.INSTALL CHAIN SUB-ASSEMBLY
13050
17.INSTALL CAMSHAFT TIMING GEAR ASSEMBLY
13507A
18.INSTALL OIL PUMP DRIVE CHAIN SUB-ASSEMBLY
19.SET NO. 1 CYLINDER TO TDC (COMPRESSION)
11320B
20.INSTALL NO. 2 TIMING CHAIN COVER ASSEMBLY
11301C
21.INSTALL TIMING CHAIN COVER OIL SEAL
11193
22.INSTALL SPARK PLUG TUBE GASKET
11201
23.INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
16351
24.INSTALL WATER BY-PASS OUTLET
16304
25.INSTALL WATER OUTLET SUB-ASSEMBLY
13470
26.INSTALL CRANKSHAFT PULLEY ASSEMBLY
13090E
27.INSTALL CAM TIMING CONTROL MOTOR O-RING
13090D
28.INSTALL CAM TIMING CONTROL MOTOR WITH EDU ASSEMBLY
29.INSTALL O-RING
15370
30.INSTALL CAM TIMING OIL CONTROL SOLENOID ASSEMBLY
11102A
31.INSTALL CAMSHAFT POSITION SENSOR (for Exhaust Side)
11102A
32.INSTALL CAMSHAFT POSITION SENSOR (for Intake Side)
15250
33.INSTALL OIL PRESSURE CONTROL VALVE ASSEMBLY
11452D
34.INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE
19500
35.INSTALL IGNITION COIL ASSEMBLY
23255A
36.INSTALL FUEL INJECTOR SEAL
23291A
37.INSTALL INJECTOR VIBRATION INSULATOR
38.INSTALL C-RING
23256
39.INSTALL NO. 1 FUEL INJECTOR BACK-UP RING
23258
40.INSTALL NO. 3 FUEL INJECTOR BACK-UP RING
23695A
41.INSTALL NOZZLE HOLDER CLAMP
23250E
42.INSTALL DIRECT FUEL INJECTOR ASSEMBLY
23814B
43.INSTALL FUEL DELIVERY PIPE
23250F
44.INSTALL PORT FUEL INJECTOR ASSEMBLY
82125N
45.INSTALL NO. 5 ENGINE WIRE
23291
46.INSTALL INJECTOR VIBRATION INSULATOR
23891
47.INSTALL FUEL DELIVERY SPACER
23807
48.INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY
49.INSTALL WATER BY-PASS HOSE ASSEMBLY
23470
50.INSTALL FUEL PUMP LIFTER ASSEMBLY
23224D
51.INSTALL FUEL PUMP SPACER GASKET
23191
52.SET FUEL PUMP FLANGE
23100X
53.TEMPORARILY INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure)
23801P
54.TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY
23100X
55.INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure)
23801P
56.INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY
23910A
57.CONNECT FUEL TUBE SUB-ASSEMBLY
17177
58.INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET
17111
59.INSTALL INTAKE MANIFOLD
17138B
60.INSTALL INTAKE MANIFOLD STAY
16279
61.INSTALL NO. 3 WATER BY-PASS PIPE
25620
62.INSTALL EGR VALVE ASSEMBLY
16296
63.CONNECT NO. 8 WATER BY-PASS HOSE
16281
64.CONNECT NO. 4 WATER BY-PASS HOSE
25628
65.INSTALL EGR INLET GASKET
25629
66.INSTALL EGR VALVE ADAPTER GASKET
25601
67.INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY
25685
68.INSTALL NO. 1 EGR COOLER GASKET
25627
69.INSTALL EGR VALVE GASKET
25680
70.INSTALL EGR COOLER ASSEMBLY
16281
71.CONNECT NO. 4 WATER BY-PASS HOSE
16267
72.CONNECT NO. 3 WATER BY-PASS HOSE
22271
73.INSTALL THROTTLE BODY GASKET
22030
74.INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY
17141
75.INSTALL EXHAUST MANIFOLD
17118
76.INSTALL MANIFOLD STAY
17167
77.INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
23211K
78.INSTALL BRACKET
25733A
79.INSTALL NO. 1 VACUUM PIPE
80.INSTALL ENGINE HANGERS
81.REMOVE ENGINE ASSEMBLY FROM ENGINE STAND