REMOVAL AND INSTALLATION



Pre-removal Operation
  • Engine Room Under Cover Front B and Engine Room Side Cover (RH) Removal (Refer to GROUP 51 - Under Cover ).
  • Engine Coolant Draining (Refer to GROUP 14A - On-vehicle Service, Engine Coolant Replacement ).
  • Engine Oil Draining (Refer to GROUP 12 - On-vehicle Service, Engine Oil Replacement ).
  • Camshaft Removal (Refer to ).
  • Turbocharger Removal (Refer to GROUP 15 - Exhaust Manifold and Turbocharger ).
  • Inlet Manifold Removal (Refer to GROUP 15 - Inlet Manifold ).
  • Cooling Water By-pass Fitting Removal (Refer to GROUP 14A - Water Hose and Water Pipe ).
  • EGR Valve Pipe A Removal (Refer to GROUP 17 - Emission Control, Exhaust Gas Recirculation (EGR) Valve ).

Post-installation Operation
  • Engine Room Under Cover Front B and Engine Room Side Cover (RH) Installation (Refer to GROUP 51 - Under Cover ).
  • EGR Valve Pipe A Installation (Refer to GROUP 17 - Emission Control, Exhaust Gas Recirculation (EGR) Valve ).
  • Cooling Water By-pass Fitting Installation (Refer to GROUP 14A - Water Hose and Water Pipe ).
  • Inlet Manifold Installation (Refer to GROUP 15 - Inlet Manifold ).
  • Turbocharger Installation (Refer to GROUP 15 - Exhaust Manifold and Turbocharger ).
  • Camshaft Installation (Refer to ).
  • Engine Oil Refilling (Refer to GROUP 12 - On-vehicle Service, Engine Oil Replacement ).
  • Engine Coolant Refilling (Refer to GROUP 14A - On-vehicle Service, Engine Coolant Replacement ).





Removal steps
<<A>>
>>B<<
1.
Cylinder head bolt and washer assembly

>>A<<
2.
Cylinder head assembly

>>A<<
3.
Cylinder head gasket

REMOVAL SERVICE POINT



<<A>> CYLINDER HEAD BOLT AND WASHER ASSEMBLY REMOVAL



Loosen and remove the bolts in two or three steps in the order of number shown in the figure.

INSTALLATION SERVICE POINTS



>>A<< CYLINDER HEAD GASKET/CYLINDER HEAD ASSEMBLY INSTALLATION



1.
caution The thickness of the original cylinder head gasket is selected according to the protrusion amount of the piston. Therefore, if the cylinder block, piston, connecting rod or crankshaft is replaced, the protrusion amount may be changed. Always select a correct gasket by measuring the protrusion amount. (Refer to GROUP 11F - Cylinder Head and Valves ).
To replace the cylinder head gasket only, select a gasket of correct specification according to the table below.
Notch specification
Fitted thickness mm
A
1.30 ± 0.04
B
1.35 ± 0.04
C
1.40 ± 0.04

2.
caution Do not allow any foreign materials get into the coolant passages, oil passages and cylinder.
Wipe off the sealant and grease on the top surface of the cylinder block and the bottom surface of the cylinder head, and degrease the surface where the sealant is applied.

3.Apply the sealant to the top surface of the cylinder block as shown.
Specified sealant: ThreeBond 1217G or equivalent
4.Install the cylinder head gasket to the cylinder block.
note
  • Install the cylinder head gasket immediately after the application of sealant.
  • When the cylinder head gasket is installed to the cylinder block, check that the sealant is securely applied to the bead line of the cylinder head gasket.
5.Apply the sealant to the top surface of the cylinder head gasket as shown.
Specified sealant: ThreeBond 1217G or equivalent
6.
caution After the installation, until a sufficient period of time (one hour or more) elapses, do not apply the engine oil or water to the sealant application area or start the engine.
Install the cylinder head assembly.

>>B<< CYLINDER HEAD BOLT AND WASHER ASSEMBLY INSTALLATION


1.Replace the cylinder head bolt and washer assembly with new ones.
2.Apply a small amount of engine oil to the thread of the bolts and to the washers.


3.Tighten the cylinder head bolts by the following procedure (plastic region angular tightening method).
(1) Tighten the cylinder head bolts to the specified torque in the order shown in the figure in two or three steps.
Tightening torque: 50 ± 2 N·m
(2)
caution
  • When the tightening angle is smaller than the specified tightening angle, the appropriate tightening capacity cannot be secured.
  • When the tightening angle is larger than the specified tightening angle, remove the bolt to start from the beginning again according to the procedure.
Apply paint marks to the head of cylinder head bolt and the cylinder head.
(3) Tighten the cylinder head bolt in a 90° according to the tightening order.
(4) Tighten the cylinder head bolt in a 90° according to the tightening order. Check that the paint mark on the cylinder head bolt and the paint mark on the cylinder head are on a linear line.
(5) Loosen the cylinder head bolt fully.
(6) Tighten the cylinder head bolt to the specified torque again in the order shown in the figure.
Tightening torque: 50 ± 2 N·m
(7) Tighten the cylinder head bolt in a 90° according to the tightening order.
(8) Tighten the cylinder head bolt in a 90° according to the tightening order.
(9) Tighten the cylinder head bolt in a 90° according to the tightening order. Check that the paint mark on the cylinder head bolt and the paint mark on the cylinder head are at an angle of 270°.