Clean the cylinder head and the engine block surface.
Install a new coolant separator (A) in the engine block whenever the engine block is replaced.
Install a new cylinder head gasket (B) and the dowel pins (C) on the engine block. Always use a new cylinder head gasket.
Set the crankshaft to top dead center (TDC). Align the TDC mark (A) on the crankshaft sprocket with the pointer (B) on the oil pump.
Set the camshaft TDC. The UP'' mark (A) on the camshaft sprocket should be at the top, and the TDC grooves (B) on the camshaft sprocket should line up with the top edge of the head.
Install the cylinder head on the engine block.
Apply new engine oil to the threads and flange of all cylinder head bolts.
Torque the cylinder head bolts in sequence to 29 NВ·m (3.0 kgfВ·m, 22 lbfВ·ft) with a beam-type torque wrench if possible. When using a preset click-type torque wrench, be sure to tighten slowly and do not overtighten. If a bolt makes any noise while you are torquing it, loosen the bolt and retighten it from the first step.
Tighten all cylinder head bolts an additional 130 В°.
Install the cam chain.
Install the cylinder head cover.
Install the harness holder (A), then install the ground cable (B).
Install the harness holder (A) to the fuel rail.
Connect the following engine wire harness connectors, and install the wire harness clamps to the cylinder head:
Four injector connectors
ECT sensor 1 connector
CMP sensor connector
Secondary HO2S connector
Rocker arm oil control solenoid connector
Install the warm up TWC.
Install the intake manifold/chamber assembly.
Connect the upper radiator hose (A), the heater hose (B), and the water bypass hose (C).
Install the heater hose to the clamps (D).
Connect the fuel feed hose (A), then install the quick-connect fitting cover (B) and the fuel feed hose clamp (C).
Install the air cleaner.
After installation, check that all tubes, hoses, and connectors are installed correctly.
Do the battery installation procedure.
Inspect for fuel leaks. Turn the ignition switch to ON (II) (do not operate the starter) so the fuel pump runs for about 2 seconds and pressurizes the fuel line. Repeat this operation three times, then check for fuel leakage at any point in the fuel line.
Refill the radiator with engine coolant, and bleed the air from the cooling system.
Clean up any spilled engine coolant.
Do the CKP pattern clear/CKP pattern learn procedure.
Inspect the idle speed.
Inspect the ignition timing.
M/T Differential Backlash Inspection (M/T)
Place the differential assembly on V-blocks (A), and install the right driveshaft (B) and the left driveshaft (C). Measure the backlash of both pinion gears (D) with a dial in ...
Tailgate Lock Cylinder Replacement
For Some Models NOTE: Put on gloves to protect your hands. Remove the tailgate lower trim panal. Disconnect the tailgate cylinder rod (A). NOTE: Check for damaged or stress-wh ...
Main Valve Body Disassembly, Inspection, and Reassembly (A/T)
Clean all parts thoroughly in solvent, and dry them with compressed air. Blow out all passages. Do not use a magnet to remove the check balls, it may magnetize the check balls. ...