RM38T0EC _51 Engine / Hybrid System _144958 M20F-FXS, M20G-FXS ENGINE MECHANICAL _0604259 CYLINDER HEAD GASKET A

M20F-FXS, M20G-FXS ENGINE MECHANICAL  CYLINDER HEAD GASKET  INSTALLATION  


CAUTION / NOTICE / HINT

NOTICE:

This procedure includes the installation of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.

Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION


CAUTION / NOTICE / HINT

COMPONENTS (INSTALLATION)
A528809N02
2.115,2.365 2.948,2.531 0.833,0.167 1.094,2.667 1.427,2.833 0.333,0.167 1.052,2.625 1.469,2.875 0.417,0.25 4.792,0.5 5.625,0.667 0.833,0.167 4.542,0.229 5.292,0.396 0.75,0.167 2.552,0.083 3.302,0.25 0.75,0.167 3.229,0.5 3.719,0.5 false 1.771,0.906 3.833,0.906 false 2.177,1.417 2.177,0.917 false 2.76,1.344 2.76,0.917 false 3.156,1.26 3.156,0.917 false 3.563,1.135 3.563,0.917 false 4.094,1.635 4.365,1.396 4.365,1.396 4.531,1.396 false 3.313,0.167 3.646,0.167 false 4.927,2.698 5.438,2.333 5.438,2.333 5.604,2.333 false 1.427,2.76 2.344,2.76 2.344,2.76 2.344,2.958 false 1.979,3.083 1.979,2.76 false 2.958,2.448 3.625,2.448 false 4.469,0.708 4.625,0.573 4.625,0.573 4.792,0.573 false 4.073,0.552 4.375,0.313 4.375,0.313 4.542,0.313 false 4.521,1.938 4.854,1.938 false 4.802,3.104 5.427,2.719 5.427,2.719 5.594,2.719 false 4.729,3.281 5.385,3.625 5.385,3.625 5.552,3.625 false 5.135,4.125 5.552,4.125 false 3.042,4.927 3.375,4.927 false 4.156,2.302 4.417,2.177 4.417,2.177 4.583,2.177 false 2.854,4.74 3.208,5.156 0.354,0.417 18 false 1 5.823,3.99 6.146,4.406 0.323,0.417 18 false 2 4.813,1.25 5.135,1.667 0.323,0.417 18 false 3 5.146,1.771 5.469,2.188 0.323,0.417 18 false 4 1.594,0.74 1.917,1.156 0.323,0.417 18 false 5 5.844,3.469 6.167,3.885 0.323,0.417 18 false 6 5.865,2.583 6.188,3 0.323,0.417 18 false 7 5.854,2.188 6.177,2.604 0.323,0.417 18 false 8 2.635,0.083 3.302,0.271 0.667,0.188 8 false 10 (102, 7) 4.604,0.24 5.458,0.458 0.854,0.219 8 false 16 (163, 12) 4.844,0.51 5.75,0.688 0.906,0.177 8 false 28.5 (291, 21) 2.177,2.375 3.26,2.542 1.083,0.167 8 false 28.5 (291, 21) 1.146,2.667 1.438,2.875 0.292,0.208 10 false *T1 2.719,4.813 2.875,5.052 0.156,0.24 10 false 3.75,0.104 3.969,0.344 0.219,0.24 10 false x2 4.135,0.625 4.354,0.865 0.219,0.24 10 false x9 4.521,0.76 4.844,0.99 0.323,0.229 10 false x14 4.865,3.042 5.188,3.271 0.323,0.229 10 false x16 4.427,3.208 4.75,3.438 0.323,0.229 10 false x16 2.469,3.281 2.792,3.51 0.323,0.229 10 false x6 2.531,3.51 2.854,3.74 0.323,0.229 10 false x6 2.115,3.552 2.438,3.781 0.323,0.229 10 false x4 3.729,2.427 4.052,2.656 0.323,0.229 10 false x3 4.208,2.292 4.531,2.521 0.323,0.229 10 false x10 3.042,0.354 3.365,0.771 0.323,0.417 18 false 9 4.646,2.083 4.802,2.323 0.156,0.24 10 false

Procedure Part Name Code
Z101186

Z101188

Z101187

1 CYLINDER HEAD GASKET 11115 (Click here) - -
2 CYLINDER HEAD SUB-ASSEMBLY 11101 (Click here) - -
3 EXHAUST CAMSHAFT SUB-ASSEMBLY 13502B (Click here) - -
4 INTAKE CAMSHAFT SUB-ASSEMBLY 13501A (Click here) - -
5 CAMSHAFT BEARING CAP - (Click here) - -
6 VALVE LASH ADJUSTER ASSEMBLY 13750 (Click here) - -
7 NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY 13801 (Click here) - -
8 CAMSHAFT HOUSING SUB-ASSEMBLY 11103 (Click here) - -
9 FUEL PUMP LIFTER GUIDE 23477 (Click here) - -

V111893

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf)
V100146

N*m (kgf*cm, ft.*lbf): Specified torque
Non-reusable part - -
*T1 1st: 50 (510, 37)
2nd: Turn 90°
3rd: Turn 90°
- -

A535977N01
3.323,0.094 4.823,0.802 1.5,0.708 1.958,1.156 2.708,1.323 0.75,0.167 3.99,0.146 4.74,0.313 0.75,0.167 0.26,2.021 1.01,2.188 0.75,0.167 0.26,1.719 1.01,1.885 0.75,0.167 1.115,2.406 1.865,2.573 0.75,0.167 0.198,3.875 0.948,4.042 0.75,0.167 0.135,5.188 0.885,5.354 0.75,0.167 1.615,5.49 2.365,5.656 0.75,0.167 1.521,0.823 2.271,0.99 0.75,0.167 4.729,3.365 5.479,3.531 0.75,0.167 0.094,5.146 0.927,5.396 0.833,0.25 2.865,1.042 3.615,1.208 0.75,0.167 2.719,1.25 3.271,1.25 3.271,1.25 3.385,1.896 false 6.635,0.177 6.865,0.177 false 4.833,0.385 5.167,0.385 false 3.563,0.385 3.813,0.219 3.813,0.219 3.979,0.219 false 2.573,0.333 2.74,0.333 2.74,0.333 2.969,0.719 false 2.281,0.906 2.615,0.906 false 2.375,5.583 2.729,5.583 false 2.448,5.25 2.646,5.25 false 3.417,5.313 3.75,5.313 false 0.583,3.875 0.583,3.708 0.583,3.708 0.854,3.656 false 1.531,4.625 1.813,4.625 false 0.896,5.271 1.063,5.271 1.063,5.271 1.188,5.083 false 1.49,3.563 1.625,3.792 1.625,3.792 1.802,3.792 false 3.594,3.833 3.594,3.5 false 1.563,2.833 1.719,2.833 1.719,2.833 2.042,2.958 false 1.875,2.49 2.042,2.49 2.042,2.49 2.167,2.698 false 1.021,2.104 1.354,2.104 false 1.021,1.792 1.188,1.792 1.188,1.792 1.438,1.927 false 2.198,2.208 2.531,2.208 false 1.396,1.354 1.563,1.354 1.563,1.354 1.75,1.854 false 4.021,1.438 4.198,1.438 false 3.729,2.156 3.906,2.156 false 2.719,1.583 2.896,1.583 false 4.24,2.865 4.563,3.448 4.563,3.448 4.729,3.448 false 3.625,1.125 3.729,1.125 3.729,1.125 3.792,1.177 false 0.75,3.24 1.083,3.24 false 1.146,3.99 1.146,3.656 false 3.823,3.75 3.823,3.417 false 3.698,1.302 4.25,1.656 0.552,0.354 18 false 10 5.417,0.25 5.969,0.604 0.552,0.354 18 false 11 3.927,1.99 4.479,2.344 0.552,0.354 18 false 13 1.875,2.052 2.427,2.406 0.552,0.354 18 false 14 1.073,1.229 1.625,1.583 0.552,0.354 18 false 15 2.271,0.188 2.823,0.542 0.552,0.354 18 false 17 1.833,3.656 2.385,4.01 0.552,0.354 18 false 18 5.896,0.031 6.781,0.302 0.885,0.271 18 false 12, 19 4.031,5.146 4.583,5.5 0.552,0.354 18 false 20 2.156,5.083 2.708,5.438 0.552,0.354 18 false 21 1.677,5.5 2.49,5.677 0.813,0.177 8 false 24 (245, 18) 0.208,5.188 1.021,5.365 0.813,0.177 8 false 43 (438, 32) 0.271,3.875 1.083,4.052 0.813,0.177 8 false 50 (510, 37) 1.198,2.417 2.01,2.594 0.813,0.177 8 false 24 (245, 18) 0.354,2.021 1.167,2.198 0.813,0.177 8 false 10 (102, 7) 0.354,1.729 1.167,1.906 0.813,0.177 8 false 10 (102, 7) 2.021,1.167 2.833,1.344 0.813,0.177 8 false 24 (245, 18) 4.052,0.146 4.865,0.323 0.813,0.177 8 false 19 (194, 14) 1.583,0.823 2.396,1 0.813,0.177 8 false 86 (877, 63) 3.438,1.938 3.75,2.135 0.313,0.198 10 false x2 2.573,5.625 2.885,5.823 0.313,0.198 10 false x20 1.292,5.052 1.604,5.25 0.313,0.198 10 false x3 3.917,1.156 4.229,1.354 0.313,0.198 10 false x9 4,2.865 4.313,3.063 0.313,0.198 10 false x11 2.385,1.427 2.938,1.781 0.552,0.354 18 false 16 3.604,0.438 3.917,0.635 0.313,0.198 10 false x3 4.781,3.365 5.594,3.542 0.813,0.177 8 false 27 (275, 20) 2.927,1.052 3.74,1.229 0.813,0.177 8 false 27 (275, 20) 1.354,2.75 1.667,2.948 0.313,0.198 10 false *1 0.573,3.156 0.885,3.354 0.313,0.198 10 false *2 1.063,4.01 1.375,4.208 0.313,0.198 10 false *3 3.552,3.875 3.865,4.073 0.313,0.198 10 false *4 3.771,3.781 4.083,3.979 0.313,0.198 10 false *5 1.354,4.542 1.667,4.74 0.313,0.198 10 false *6 2.031,5.115 2.344,5.313 0.313,0.198 10 false

Procedure Part Name Code
Z101186

Z101188

Z101187

10 TIMING CHAIN COVER ASSEMBLY 11310 (Click here) - -
11 CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY 13070A (Click here) - -
12 SET NO. 1 CYLINDER TO TDC (COMPRESSION) - (Click here) - -
13 NO. 1 CHAIN VIBRATION DAMPER 13561 - - -
14 CHAIN TENSIONER SLIPPER 13559 - - -
15 NO. 1 CHAIN TENSIONER ASSEMBLY 13540 (Click here) - -
16 CHAIN SUB-ASSEMBLY 13506 (Click here) - -
17 CAMSHAFT TIMING GEAR ASSEMBLY 13050 (Click here) - -
18 OIL PUMP DRIVE CHAIN SUB-ASSEMBLY 13507A (Click here) - -
19 SET NO. 1 CYLINDER TO TDC (COMPRESSION) - (Click here) - -
20 NO. 2 TIMING CHAIN COVER ASSEMBLY 11320B (Click here) - -
21 TIMING CHAIN COVER OIL SEAL 11301C (Click here) - -

V111893

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf)
V100146

N*m (kgf*cm, ft.*lbf): Specified torque
Non-reusable part
V100135

MP grease
V103638

Do not apply lubricants to the threaded parts - -

A529530N01
0.802,0.969 1.802,1.135 1,0.167 2.115,0.094 3.115,0.26 1,0.167 1.813,1.052 2.167,1.052 false 3.125,0.177 3.458,0.177 false 3.823,0.458 4.156,0.458 false 4.635,0.938 4.969,0.938 false 4.479,1.958 4.813,1.958 false 3.26,2.188 3.49,2.479 3.49,2.479 3.656,2.479 true 2.51,2.563 2.844,2.563 false 2.167,0.094 3.188,0.26 1.021,0.167 8 false 7.5 (76, 66 in.*lbf) 1.865,0.104 2.125,0.302 0.26,0.198 10 false ●★ 0.865,0.969 1.885,1.135 1.021,0.167 8 false 7.5 (76, 66 in.*lbf) 4.865,1.844 5.125,2.042 0.26,0.198 10 false 3.708,2.354 3.969,2.552 0.26,0.198 10 false 2.365,2.448 2.625,2.646 0.26,0.198 10 false 4.208,0.365 4.469,0.563 0.26,0.198 10 false 4.333,0.302 4.885,0.656 0.552,0.354 18 false 22 5.24,0.781 5.792,1.135 0.552,0.354 18 false 23 3.823,0.479 4.083,0.677 0.26,0.198 10 false x4 3.604,0.167 3.865,0.365 0.26,0.198 10 false x4 2.281,1.01 2.583,1.208 0.302,0.198 10 false x12 3.385,2.063 3.688,2.26 0.302,0.198 10 false x6

Procedure Part Name Code
Z101186

Z101188

Z101187

22 SPARK PLUG TUBE GASKET 11193 - - -
23 CYLINDER HEAD COVER SUB-ASSEMBLY 11201 (Click here) - -

V100146

N*m (kgf*cm, ft.*lbf): Specified torque Non-reusable part
Precoated part - -

A528818N02
5.583,0.083 7.083,1.833 1.5,1.75 6.333,0.917 7,1.083 0.667,0.167 2.917,1.583 3.917,1.75 1,0.167 1.865,0.052 2.865,0.219 1,0.167 5.938,4.948 6.604,5.115 0.667,0.167 5.802,3.521 6.469,3.688 0.667,0.167 0.281,1.396 0.948,1.563 0.667,0.167 0.729,3.24 1.479,3.406 0.75,0.167 0.771,3.688 1.438,3.854 0.667,0.167 0.927,4.635 1.927,4.802 1,0.167 3.833,0.76 4.833,0.927 1,0.167 2.875,1.542 3.958,1.792 1.083,0.25 3.792,0.719 4.875,0.969 1.083,0.25 2.865,0.635 3.188,0.635 false 2.875,0.135 3.292,0.135 false 4.469,0.729 4.469,0.563 4.469,0.563 4.896,0.469 false 6.656,0.906 6.656,0.74 6.656,0.74 6.219,0.656 false 6.094,1.625 6.49,1.625 false 6.656,2 6.656,1.833 false 5.302,1.5 5.302,1.333 5.302,1.333 5.094,1.115 false 6.229,2.656 6.573,2.656 false 6.479,3.604 6.646,3.604 6.646,3.604 6.948,2.99 false 6.073,3.885 5.906,3.885 5.906,3.885 5.854,4.094 false 6.615,5.031 6.781,5.031 6.781,5.031 7.031,4.25 false 6.052,4.667 6.219,4.667 6.219,4.667 6.354,4.313 false 5.729,3.021 5.563,3.021 5.563,3.021 5.563,3.26 false 2.583,1.948 2.927,1.948 false 3.365,1.583 3.365,1.479 3.365,1.479 2.563,1.479 false 0.75,0.719 0.917,0.719 0.917,0.719 1.021,0.979 false 1.167,0.281 1.333,0.281 1.333,0.281 1.51,0.771 false 0.677,1.854 0.844,1.854 0.844,1.854 0.958,2.104 false 1.792,5.531 1.625,5.531 1.625,5.531 1.521,5.385 false 0.917,4.719 0.75,4.719 0.75,4.719 0.406,5.417 false 0.771,3.771 0.604,3.771 0.604,3.771 0.396,4.219 false 0.729,3.323 0.563,3.323 0.563,3.323 0.26,2.688 false 0.563,1.167 0.563,1.385 false 1.469,2.427 1.469,2.844 false 0.792,4.094 1.104,4.094 false 6.385,0.927 7,1.115 0.615,0.188 8 false 10 (102, 7) 5.854,3.521 6.469,3.708 0.615,0.188 8 false 10 (102, 7) 5.99,4.948 6.604,5.135 0.615,0.188 8 false 10 (102, 7) 1.042,4.635 1.979,4.823 0.938,0.188 8 false 260 (2651, 192) 0.823,3.688 1.438,3.875 0.615,0.188 8 false 10 (102, 7) 0.792,3.25 1.625,3.49 0.833,0.24 8 false 21 (214, 15) 0.344,1.406 1,1.594 0.656,0.188 8 false 10 (102, 7) 2.938,1.594 3.979,1.792 1.042,0.198 8 false 7.5 (76, 66 in.*lbf) 1.906,0.063 2.948,0.26 1.042,0.198 8 false 7.5 (76, 66 in.*lbf) 0.063,1.385 0.375,1.583 0.313,0.198 10 false ●★ 2.635,1.594 2.948,1.792 0.313,0.198 10 false ●★ 3.885,0.76 4.927,0.958 1.042,0.198 8 false 7.5 (76, 66 in.*lbf) 6.833,2.49 7.146,2.833 0.313,0.344 18 false 24 5.719,4.5 6.271,4.854 0.552,0.354 18 false 25 2.073,5.375 2.625,5.729 0.552,0.354 18 false 26 1.531,2.813 2.083,3.167 0.552,0.354 18 false 27 0.344,1.677 0.896,2.031 0.552,0.354 18 false 28 0.844,0.135 1.396,0.49 0.552,0.354 18 false 29 0.427,0.573 0.979,0.927 0.552,0.354 18 false 30 3.167,1.823 3.719,2.177 0.552,0.354 18 false 31 5.281,1.542 5.833,1.896 0.552,0.354 18 false 32 1.385,3.958 1.938,4.313 0.552,0.354 18 false 33 6.521,1.99 7.073,2.344 0.552,0.354 18 false 34 2.563,0.49 3.115,0.844 0.552,0.354 18 false 35 1.406,2.865 1.719,3.063 0.313,0.198 10 false 3.542,0.74 3.854,0.938 0.313,0.198 10 false ●★ 6.552,1.521 6.865,1.719 0.313,0.198 10 false 6.948,3.01 7.156,3.208 0.208,0.198 10 false x3 6.146,3.76 6.458,3.958 0.313,0.198 10 false 5.76,2.906 6.073,3.104 0.313,0.198 10 false 0.604,1.156 0.813,1.354 0.208,0.198 10 false x2 0.354,2.656 0.563,2.854 0.208,0.198 10 false x3 6.813,4.229 7.021,4.427 0.208,0.198 10 false x2 3.458,0.385 3.667,0.583 0.208,0.198 10 false x4 3.385,0.052 3.594,0.25 0.208,0.198 10 false x4

Procedure Part Name Code
Z101186

Z101188

Z101187

24 WATER BY-PASS OUTLET 16351 (Click here) - -
25 WATER OUTLET SUB-ASSEMBLY 16304 - - -
26 CRANKSHAFT PULLEY ASSEMBLY 13470 (Click here) - -
27 CAM TIMING CONTROL MOTOR O-RING 13090E (Click here) - -
28 CAM TIMING CONTROL MOTOR WITH EDU ASSEMBLY 13090D (Click here) - -
29 O-RING - (Click here) - -
30 CAM TIMING OIL CONTROL SOLENOID ASSEMBLY 15370 (Click here) - -
31 CAMSHAFT POSITION SENSOR (for Exhaust Side) 11102A (Click here) - -
32 CAMSHAFT POSITION SENSOR (for Intake Side) 11102A (Click here) - -
33 OIL PRESSURE CONTROL VALVE ASSEMBLY 15250 (Click here) - -
34 ENGINE OIL LEVEL DIPSTICK GUIDE 11452D - - -
35 IGNITION COIL ASSEMBLY 19500 (Click here) - -

V111893

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf)
V100146

N*m (kgf*cm, ft.*lbf): Specified torque
Non-reusable part Precoated part

A528812N02
3.01,0.865 3.844,1.198 0.833,0.333 2.969,0.823 3.885,1.24 0.917,0.417 5.646,0.104 6.479,0.438 0.833,0.333 5.604,0.063 6.521,0.479 0.917,0.417 6.094,1.094 6.927,1.26 0.833,0.167 6.052,1.052 6.969,1.302 0.917,0.25 3.167,0.125 3.917,0.292 0.75,0.167 3.125,0.083 3.958,0.333 0.833,0.25 0.25,5.563 1.083,5.729 0.833,0.167 0.115,2.927 0.948,3.094 0.833,0.167 0.073,2.885 0.99,3.135 0.917,0.25 1.927,1.125 2.26,1.125 false 3.615,4.292 3.448,4.292 3.448,4.292 3.146,4.979 false 3.521,3.99 3.354,3.99 3.354,3.99 2.979,4.917 false 3.396,3.625 3.229,3.625 3.229,3.625 2.813,4.854 false 2.292,5.417 2.625,5.417 false 1.094,5.646 1.427,5.646 false 2.521,4.188 2.354,4.188 2.354,4.188 2.292,4.375 false 1.938,5.073 2.104,5.073 2.104,5.073 2.271,4.781 false 0.74,5.177 0.906,5.177 0.906,5.177 1.948,4.594 false 1.271,4.563 1.438,4.563 1.438,4.563 1.708,4.51 false 0.969,4.833 1.135,4.833 1.135,4.833 1.833,4.552 false 1.219,3.563 1.5,3.563 false 0.958,3.01 1.125,3.01 1.125,3.01 1.198,3.323 false 2.51,2.896 2.844,2.896 false 2.615,3.385 2.781,3.385 2.781,3.385 2.969,3.125 false 2.188,2.302 2.354,2.302 2.354,2.302 2.479,2.365 false 3.365,2.51 3.698,2.51 false 4.229,1.792 4.229,1.448 false 5.26,2.104 5.594,2.104 false 4.031,0.615 4.333,0.615 false 3.854,1.01 4.021,1.01 4.021,1.01 4.365,1.052 false 3.927,0.208 4.094,0.208 4.094,0.208 4.542,0.104 false 5.625,0.25 5.458,0.25 5.458,0.25 5.094,0.302 false 5.854,0.667 5.688,0.667 5.688,0.667 5.521,0.813 false 6.5,1.052 6.5,0.885 6.5,0.885 5.938,0.875 false 5.438,1.833 5.979,1.833 false 5.813,1.354 5.646,1.354 5.646,1.354 5.406,1.25 false 5.583,1.573 6.542,1.573 false 2.219,2.49 2.385,2.49 2.385,2.49 2.74,2.708 false 2.667,5.229 3.219,5.583 0.552,0.354 18 false 49 3.896,3.823 4.375,4.125 0.479,0.302 18 false 38 3.979,4.156 4.375,4.438 0.396,0.281 18 false 36 1.667,4.323 1.979,4.521 0.313,0.198 10 false x4 1.833,4.375 2.146,4.573 0.313,0.198 10 false x4 1.979,4.448 2.292,4.646 0.313,0.198 10 false x4 2.302,4.771 2.615,4.969 0.313,0.198 10 false x4 2.698,4.917 3.01,5.115 0.313,0.198 10 false x4 2.917,4.979 3.229,5.177 0.313,0.198 10 false x4 3.156,5 3.469,5.198 0.313,0.198 10 false x4 0.813,4.448 1,4.646 0.188,0.198 10 false 0.323,5.031 0.51,5.229 0.188,0.198 10 false 5.958,0.885 6.271,1.083 0.313,0.198 10 false x2 2.979,3.104 3.292,3.302 0.313,0.198 10 false x4 1.219,3.167 1.531,3.365 0.313,0.198 10 false x4 3.26,0.125 3.927,0.333 0.667,0.208 8 false 10 (102, 7) 3.115,0.885 3.948,1.052 0.833,0.167 8 false 35 (357, 26) 3.115,1.031 3.948,1.198 0.833,0.167 8 false 30 (306, 22)* 5.719,0.271 6.552,0.438 0.833,0.167 8 false 30 (306, 22)* 5.719,0.125 6.552,0.292 0.833,0.167 8 false 35 (357, 26) 6.146,1.094 7.031,1.281 0.885,0.188 8 false 28.5 (291, 21) 0.177,2.927 1.063,3.115 0.885,0.188 8 false 28.5 (291, 21) 0.333,5.573 1.052,5.75 0.719,0.177 8 false 21 (214, 15) 3.854,4.219 4.042,4.417 0.188,0.198 10 false 3.771,3.927 3.958,4.125 0.188,0.198 10 false 0.844,4.719 1.031,4.917 0.188,0.198 10 false 3.646,3.531 3.833,3.729 0.188,0.198 10 false 3.771,3.458 4.25,3.76 0.479,0.302 18 false 37 2.396,4.354 2.708,4.552 0.313,0.198 10 false x4 2.563,4.021 3.115,4.375 0.552,0.354 18 false 41 1.635,4.896 2.188,5.25 0.552,0.354 18 false 42 0.417,5 0.969,5.354 0.552,0.354 18 false 39 0.938,4.385 1.49,4.74 0.552,0.354 18 false 40 0.917,3.406 1.469,3.76 0.552,0.354 18 false 43 2.74,2.948 3.052,3.146 0.313,0.198 10 false x4 2.604,2.698 2.917,2.896 0.313,0.198 10 false x4 2.302,3.208 2.854,3.563 0.552,0.354 18 false 46 2.208,2.729 2.76,3.083 0.552,0.354 18 false 44 1.875,2.146 2.427,2.5 0.552,0.354 18 false 48 2.177,3.26 2.365,3.458 0.188,0.198 10 false 2.542,1.896 2.854,2.094 0.313,0.198 10 false x2 3.76,2.323 4.24,2.625 0.479,0.302 18 false 47 3.365,2.531 3.677,2.729 0.313,0.198 10 false x2 4.25,1.781 4.729,2.083 0.479,0.302 18 false 57 5.865,1.948 6.344,2.25 0.479,0.302 18 false 50 1.583,0.958 2.135,1.313 0.552,0.354 18 false 45 3.281,0.448 4.188,0.76 0.906,0.313 18 false 54, 56 6.125,0.521 7.031,0.833 0.906,0.313 18 false 53, 55 6.031,1.729 6.219,1.927 0.188,0.198 10 false 6.167,1.635 6.646,1.938 0.479,0.302 18 false 51 5.865,1.24 6.052,1.438 0.188,0.198 10 false 6.615,1.375 7.094,1.677 0.479,0.302 18 false 52 2.104,2.385 2.292,2.583 0.188,0.198 10 false

Procedure Part Name Code
Z101186

Z101188

Z101187

36 FUEL INJECTOR SEAL 23255A (Click here) - -
37 INJECTOR VIBRATION INSULATOR 23291A (Click here) - -
38 C-RING - (Click here) - -
39 NO. 1 FUEL INJECTOR BACK-UP RING 23256 (Click here) - -
40 NO. 3 FUEL INJECTOR BACK-UP RING 23258 (Click here) - -
41 NOZZLE HOLDER CLAMP 23695A - - -
42 DIRECT FUEL INJECTOR ASSEMBLY 23250E (Click here) - -
43 FUEL DELIVERY PIPE 23814B (Click here) - -
44 PORT FUEL INJECTOR ASSEMBLY 23250F (Click here) - -
45 NO. 5 ENGINE WIRE 82125N - - -
46 INJECTOR VIBRATION INSULATOR 23291 - - -
47 FUEL DELIVERY SPACER 23891 - - -
48 FUEL DELIVERY PIPE SUB-ASSEMBLY 23807 (Click here) - -
49 WATER BY-PASS HOSE ASSEMBLY - - - -
50 FUEL PUMP LIFTER ASSEMBLY 23470 (Click here) - -
51 FUEL PUMP SPACER GASKET 23224D - - -
52 FUEL PUMP FLANGE 23191 - - -
53 TEMPORARILY INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure) 23100X (Click here) - -
54 TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY 23801P (Click here) - -
55 FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure) 23100X (Click here) - -
56 NO. 1 FUEL PIPE SUB-ASSEMBLY 23801P (Click here) - -
57 CONNECT FUEL TUBE SUB-ASSEMBLY 23910A (Click here) - -

V111893

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf)
V100146

N*m (kgf*cm, ft.*lbf): Specified torque
* For use with a union nut wrench Non-reusable part

A528813N01
0.063,1.271 0.729,1.438 0.667,0.167 0.75,0.021 1.417,0.188 0.667,0.167 5.542,5.448 6.208,5.615 0.667,0.167 6.396,5.615 7.063,5.781 0.667,0.167 5.563,3.458 6.229,3.625 0.667,0.167 4.01,2.365 4.677,2.531 0.667,0.167 5.865,1.01 6.531,1.177 0.667,0.167 0.063,1.052 0.729,1.219 0.667,0.167 0.688,2.583 1.354,2.75 0.667,0.167 0.073,3.188 0.74,3.354 0.667,0.167 2.531,2.844 3.198,3.01 0.667,0.167 0.594,0.167 0.615,0.083 0.615,0.083 0.74,0.083 false 0.427,3.188 0.427,2.854 false 6.729,5.604 6.729,5.271 false 5.875,5.448 5.875,5.281 5.875,5.281 6.25,5.208 false 4.625,5.375 4.865,5.375 false 4.802,4.76 4.802,4.594 4.802,4.594 5.146,4.354 false 6.615,4.833 6.948,4.833 false 0.427,2.073 0.51,2.667 0.51,2.667 0.677,2.667 false 1.479,0.25 1.792,0.167 1.792,0.167 1.958,0.167 false 4.635,3.938 4.781,3.125 4.781,3.125 4.948,3.125 false 5.229,3.542 5.563,3.542 false 3.979,4.542 4.313,4.542 false 5.646,3.823 5.979,3.823 false 5.958,4.5 6.094,4.125 6.094,4.125 6.26,4.125 false 3.073,2.51 3.177,2.729 3.177,2.729 3.344,2.729 false 3.781,1.917 3.875,2.115 3.875,2.115 4.042,2.115 false 3.667,2.438 4,2.438 false 4.771,1.656 4.938,2.042 4.938,2.042 5.104,2.042 false 5.531,1.083 5.865,1.083 false 3.313,0.938 3.646,0.938 false 1.813,0.479 2.146,0.479 false 0.719,0.781 0.885,0.781 0.885,0.781 0.969,0.604 false 0.583,1.625 0.917,1.625 false 0.74,1.344 0.906,1.344 0.906,1.344 0.927,1.552 false 0.729,1.146 0.896,1.146 0.896,1.146 0.917,1.042 false 1.271,3.51 1.271,3.302 false 2.073,2.188 2.073,1.979 false 2.229,2.625 2.344,2.917 2.344,2.917 2.51,2.917 false 0.813,0.021 1.531,0.198 0.719,0.177 8 false 10 (102, 7) 0.094,1.271 0.813,1.448 0.719,0.177 8 false 24 (245, 18) 0.708,2.583 1.427,2.76 0.719,0.177 8 false 24 (245, 18) 0.115,1.042 0.833,1.219 0.719,0.177 8 false 10 (102, 7) 0.135,3.188 0.854,3.365 0.719,0.177 8 false 10 (102, 7) 5.573,5.448 6.292,5.625 0.719,0.177 8 false 24 (245, 18) 6.427,5.625 7.104,5.802 0.677,0.177 8 false 24 (245, 18) 4.323,5.25 4.875,5.604 0.552,0.354 18 false 68 4.188,5.281 4.344,5.479 0.156,0.198 10 false 4.865,4.74 5.417,5.094 0.552,0.354 18 false 69 4.75,4.781 4.906,4.979 0.156,0.198 10 false 5.229,3 5.781,3.354 0.552,0.354 18 false 62 6.833,5.135 7.063,5.344 0.229,0.208 10 false *a 6.354,5.177 6.583,5.385 0.229,0.208 10 false *b 6.292,4.698 6.844,5.052 0.552,0.354 18 false 72 5.625,3.458 6.344,3.635 0.719,0.177 8 false 10 (102, 7) 5.219,3.563 5.448,3.771 0.229,0.208 10 false x2 3.656,4.385 4.208,4.74 0.552,0.354 18 false 63 6.031,3.667 6.969,4 0.938,0.333 18 false 64, 71 6.521,3.99 7.073,4.344 0.552,0.354 18 false 70 3.625,2.625 4.177,2.979 0.552,0.354 18 false 60 4.313,2.01 4.469,2.208 0.156,0.198 10 false 4.448,1.979 5,2.333 0.552,0.354 18 false 73 4.063,2.375 4.781,2.552 0.719,0.177 8 false 10 (102, 7) 5.365,1.906 5.917,2.26 0.552,0.354 18 false 74 5.917,1.01 6.635,1.188 0.719,0.177 8 false 10 (102, 7) 5.469,1.104 5.698,1.313 0.229,0.208 10 false x3 2.927,1.094 3.156,1.302 0.229,0.208 10 false x3 3.688,0.833 3.844,1.031 0.156,0.198 10 false 3.802,0.781 4.354,1.135 0.552,0.354 18 false 58 2.198,0.375 2.354,0.573 0.156,0.198 10 false 2.313,0.333 2.865,0.688 0.552,0.354 18 false 66 2,0.063 2.156,0.26 0.156,0.198 10 false 2.146,0.021 2.698,0.375 0.552,0.354 18 false 65 0.448,0.625 1,0.979 0.552,0.354 18 false 67 0.271,1.5 0.823,1.854 0.552,0.354 18 false 59 0.948,1.01 1.177,1.219 0.229,0.208 10 false x2 0.219,2.021 0.448,2.229 0.229,0.208 10 false x2 1.302,3.51 1.854,3.865 0.552,0.354 18 false 61 2.083,2.208 2.635,2.563 0.552,0.354 18 false 59 2.563,2.844 3.281,3.021 0.719,0.177 8 false 21 (214, 15) 0.365,0.094 0.594,0.302 0.229,0.208 10 false x2

Procedure Part Name Code
Z101186

Z101188

Z101187

58 NO. 1 INTAKE MANIFOLD TO HEAD GASKET 17177 - - -
59 INTAKE MANIFOLD 17111 (Click here) - -
60 INTAKE MANIFOLD STAY 17138B (Click here) - -
61 NO. 3 WATER BY-PASS PIPE 16279 (Click here) - -
62 EGR VALVE ASSEMBLY 25620 (Click here) - -
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 (Click here) - -
68 NO. 1 EGR COOLER GASKET 25685 (Click here) - -
69 EGR VALVE GASKET 25627 (Click here) - -
70 EGR COOLER ASSEMBLY 25680 (Click here) - -
71 CONNECT NO. 4 WATER BY-PASS HOSE 16281 - - -
72 CONNECT NO. 3 WATER BY-PASS HOSE 16267 - - -
73 THROTTLE BODY GASKET 22271 (Click here) - -
74 THROTTLE BODY WITH MOTOR ASSEMBLY 22030 (Click here) - -

*a x2 or x3 *b x3 or x2
V100146

N*m (kgf*cm, ft.*lbf): Specified torque Non-reusable part

A545656N01
3.51,3.385 4.26,3.552 0.75,0.167 5.792,4.042 6.458,4.208 0.667,0.167 5.833,4.906 6.75,5.24 0.917,0.333 6.438,3.531 7.104,3.698 0.667,0.167 2.135,5.104 2.969,5.271 0.833,0.167 4.719,1.917 5.469,2.083 0.75,0.167 4.542,0.552 5.292,0.719 0.75,0.167 3.313,0.604 3.979,0.771 0.667,0.167 2.49,2.208 3.156,2.375 0.667,0.167 6.5,0.219 6.833,0.219 false 5.99,0.844 6.323,0.844 false 5.552,1.5 5.885,1.5 false 6.198,2.271 6.323,1.917 6.323,1.917 6.49,1.917 false 5.448,4.125 5.781,4.125 false 3.406,5.5 3.74,5.5 false 2.979,5.188 3.313,5.188 false 2.344,3.073 2.677,3.073 false 4.385,1.26 4.719,1.26 false 3.365,1.854 3.448,2.125 3.448,2.125 3.615,2.125 false 3.073,3.354 3.073,3.469 3.073,3.469 3.5,3.469 false 3.198,3.458 3.198,3.146 false 5.406,4.677 5.74,4.677 false 3.146,3.865 3.313,4.031 3.313,4.031 3.479,4.031 false 6.75,3.188 6.75,3.531 false 5.469,4.979 5.688,5.063 5.688,5.063 5.833,5.063 false 5.479,2 5.813,2 false 5.302,0.635 5.521,0.635 false 3.99,0.677 4.323,0.677 false 2.813,2 2.813,2.198 false 3.563,3.385 4.313,3.552 0.75,0.167 8 false 43 (438, 32) 2.229,5.104 2.979,5.271 0.75,0.167 8 false 26 (265, 19) 5.896,4.927 6.646,5.094 0.75,0.167 8 false 30 (306, 22) 5.896,5.083 6.729,5.25 0.833,0.167 8 false 26 (265, 19)* 6.5,3.542 7.125,3.729 0.625,0.188 8 false 10 (102, 7) 5.854,4.052 6.604,4.219 0.75,0.167 8 false 10 (102, 7) 2.01,5.104 2.167,5.302 0.156,0.198 10 false 3.396,5.208 3.635,5.427 0.24,0.219 10 false x7 6.844,3.073 7.083,3.292 0.24,0.219 10 false x3 6.406,0.688 6.802,1.063 0.396,0.375 18 false 80 4.781,1.115 5.177,1.49 0.396,0.375 18 false 78 6.552,1.792 6.948,2.167 0.396,0.375 18 false 77 6.167,0.083 6.563,0.458 0.396,0.375 18 false 81 6.063,4.542 6.458,4.917 0.396,0.375 18 false 79 3.656,1.938 4.052,2.313 0.396,0.375 18 false 78 2.01,2.896 2.406,3.271 0.396,0.375 18 false 76 3.552,3.927 3.708,4.125 0.156,0.198 10 false 3.094,5.354 3.49,5.729 0.396,0.375 18 false 75 5.938,1.354 6.333,1.729 0.396,0.375 18 false 80 4.792,1.927 5.542,2.094 0.75,0.167 8 false 43 (438, 32) 4.604,0.563 5.354,0.729 0.75,0.167 8 false 43 (438, 32) 3.375,0.604 4.125,0.771 0.75,0.167 8 false 10 (102, 7) 2.552,2.208 3.302,2.375 0.75,0.167 8 false 10 (102, 7)

Procedure Part Name Code
Z101186

Z101188

Z101187

75 EXHAUST MANIFOLD 17141 (Click here) - -
76 MANIFOLD STAY 17118 - - -
77 NO. 1 EXHAUST MANIFOLD HEAT INSULATOR 17167 - - -
78 BRACKET 23211K - - -
79 NO. 1 VACUUM PIPE 25733A (Click here) - -
80 ENGINE HANGERS - - - -
81 REMOVE ENGINE ASSEMBLY FROM ENGINE STAND - (Click here) - -

V100146

N*m (kgf*cm, ft.*lbf): Specified torque * For use with a union nut wrench
Non-reusable part - -

PROCEDURE

Hide 11115 1.INSTALL CYLINDER HEAD GASKET

a.
A528098C02
3.823,1.552 3.969,1.385 false 3.708,1.552 4.021,1.708 0.313,0.156 10 false *a 0.469,0.094 0.75,0.448 0.281,0.354 18 false i
*a Lot No. - -
V100135

Front of Engine - -


i.

Clean the cylinder block sub-assembly and cylinder head sub-assembly with solvent.


ii.

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

NOTICE:

Make sure that the cylinder head gasket is installed in the correct orientation.




Hide 11101 2.INSTALL CYLINDER HEAD SUB-ASSEMBLY

Hide 13502B 3.INSTALL EXHAUST CAMSHAFT SUB-ASSEMBLY

Hide 13501A 4.INSTALL INTAKE CAMSHAFT SUB-ASSEMBLY

Hide 5.INSTALL CAMSHAFT BEARING CAP

Hide 13750 6.INSTALL VALVE LASH ADJUSTER ASSEMBLY

Hide 13801 7.INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

Hide 11103 8.INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

Hide 23477 9.INSTALL FUEL PUMP LIFTER GUIDE

Hide 11310 10.INSTALL TIMING CHAIN COVER ASSEMBLY

Hide 13070A 11.INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

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

Hide 13540 15.INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

Hide 13506 16.INSTALL CHAIN SUB-ASSEMBLY

Hide 13050 17.INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

Hide 13507A 18.INSTALL OIL PUMP DRIVE CHAIN SUB-ASSEMBLY

Hide 19.SET NO. 1 CYLINDER TO TDC (COMPRESSION)

Hide 11320B 20.INSTALL NO. 2 TIMING CHAIN COVER ASSEMBLY

Hide 11301C 21.INSTALL TIMING CHAIN COVER OIL SEAL

Hide 11201 23.INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

Hide 16351 24.INSTALL WATER BY-PASS OUTLET

Hide 13470 26.INSTALL CRANKSHAFT PULLEY ASSEMBLY

Hide 13090E 27.INSTALL CAM TIMING CONTROL MOTOR O-RING

Hide 13090D 28.INSTALL CAM TIMING CONTROL MOTOR WITH EDU ASSEMBLY

Hide 15370 30.INSTALL CAM TIMING OIL CONTROL SOLENOID ASSEMBLY

Hide 11102A 31.INSTALL CAMSHAFT POSITION SENSOR (for Exhaust Side)

Hide 11102A 32.INSTALL CAMSHAFT POSITION SENSOR (for Intake Side)

Hide 15250 33.INSTALL OIL PRESSURE CONTROL VALVE ASSEMBLY

Hide 19500 35.INSTALL IGNITION COIL ASSEMBLY

Hide 23255A 36.INSTALL FUEL INJECTOR SEAL

Hide 23291A 37.INSTALL INJECTOR VIBRATION INSULATOR

Hide 23256 39.INSTALL NO. 1 FUEL INJECTOR BACK-UP RING

Hide 23258 40.INSTALL NO. 3 FUEL INJECTOR BACK-UP RING

Hide 23250E 42.INSTALL DIRECT FUEL INJECTOR ASSEMBLY

Hide 23814B 43.INSTALL FUEL DELIVERY PIPE

Hide 23250F 44.INSTALL PORT FUEL INJECTOR ASSEMBLY

Hide 23807 48.INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

Hide 23470 50.INSTALL FUEL PUMP LIFTER ASSEMBLY

Hide 23100X 53.TEMPORARILY INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure)

Hide 23801P 54.TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

Hide 23100X 55.INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure)

Hide 23801P 56.INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

Hide 23910A 57.CONNECT FUEL TUBE SUB-ASSEMBLY

Hide 17111 59.INSTALL INTAKE MANIFOLD

Hide 17138B 60.INSTALL INTAKE MANIFOLD STAY

Hide 16279 61.INSTALL NO. 3 WATER BY-PASS PIPE

Hide 25620 62.INSTALL EGR VALVE ASSEMBLY

Hide 25601 67.INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY

Hide 25685 68.INSTALL NO. 1 EGR COOLER GASKET

Hide 25627 69.INSTALL EGR VALVE GASKET

Hide 25680 70.INSTALL EGR COOLER ASSEMBLY

Hide 22271 73.INSTALL THROTTLE BODY GASKET

Hide 22030 74.INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

Hide 17141 75.INSTALL EXHAUST MANIFOLD

Hide 17118 76.INSTALL MANIFOLD STAY

Hide 25733A 79.INSTALL NO. 1 VACUUM PIPE

Hide 81.REMOVE ENGINE ASSEMBLY FROM ENGINE STAND