CYLINDER HEAD GASKET INSTALLATION

CAUTION / NOTICE / HINT

Note


  • Always be sure to check the tightening torque.

  • If the pressure lines are leaking after installation, they must be replaced.

  • Do not overtighten the pressure lines.

PROCEDURE


  1. SELECT CYLINDER HEAD GASKET


    1. Check the piston protrusions for each cylinder.


      1. Clean the cylinder block with solvent.

      2. Set the piston of the cylinder to be measured to slightly before TDC.

      3. A004RV1E03
        Text in Illustration
        *a Measuring Tip
        *b Measuring Point
        *c Protrusion

        Using SST, place a dial indicator on the cylinder block and set the measuring tip as shown in the illustration.

        SST
        PZ4TB-04901-85

      4. Set the dial indicator at 0 mm (0 in.).

        Tech Tips

        Make sure that the measuring tip is perpendicular to the cylinder head gasket surface and piston head when taking the measurements.

      5. Find where the piston head protrudes most by slowly turning the crankshaft clockwise and counterclockwise.

      6. Measure each cylinder at 2 places for a total of 8 measurements.

      7. For the piston protrusion value of each cylinder, use the average of the 2 measurements of each cylinder.

        Standard piston protrusion
        0.420 to 0.680 mm (0.0165 to 0.0267 in.)

        If the protrusion is not as specified, remove the piston sub-assembly and connecting rod sub-assembly and reinstall them.

    2. A004PRXE02
      Text in Illustration
      *a Cylinder Head Gasket Hole
      A004NPW Front

      Select the largest piston protrusion value from the measurements and then select a new appropriate gasket according to the table below.

      Cylinder Head Gasket Size
      Item Specified Condition
      Piston Protrusion 0.42 mm (0.0165 in.) or less 0.42 to 0.53 mm (0.0165 to 0.0208 in.) 0.53 to 0.68 mm (0.0208 to 0.0267 in.)
      Cylinder Head Gasket Holes 1 Hole 2 Holes 3 Holes

      Tech Tips

      Cylinder head gaskets have 1, 2, or 3 holes.

  2. INSTALL CYLINDER HEAD GASKET


    1. Place the cylinder head gasket in position on the cylinder block.

  3. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Note


    • Do not reuse the cylinder head bolts.

    • A004TGD

      Make sure the ring pin shown in the illustration is not loose, deformed or otherwise damaged.


    1. Place the cylinder head sub-assembly on the cylinder head gasket.

      Note

      Be careful of the installation direction.

    2. A004O9X

      Using an E10 "TORX" socket wrench, temporarily install the 5 bolts.

    3. Apply a light coat of engine oil to under the heads of the new cylinder head bolts.

      Note

      Do not reuse the cylinder head bolts.

    4. Temporarily install the new cylinder head bolts.

    5. Step 1:


      1. A004N99E10

        Using an E18 "TORX" socket wrench, uniformly tighten the 10 cylinder head bolts in several steps in the sequence shown in the illustration.

        Torque:
        70 N*m  { 714 kgf*cm, 52 ft.*lbf }

      2. Mark the front of each cylinder head bolts head with paint.

      3. A004N99E09

        Loosen the cylinder head bolts by 180° in the sequence shown in the illustration.

    6. Step 2:


      1. A004N99E10

        Tighten the 10 cylinder head bolts in several steps in the sequence shown in the illustration.

        Torque:
        50 N*m  { 510 kgf*cm, 37 ft.*lbf }

      2. Retighten the cylinder head bolts by 120°.

    7. Step 3:


      1. Tighten the cylinder head bolts 120° further.

      2. Check that the paint marks are now at a 240° angle to the RH.

    8. A004O9X

      Using an E10 "TORX" socket wrench, tighten the 5 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  4. INSTALL GLOW PLUG ASSEMBLY

    Click here

  5. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH


    1. A004RP0E02

      Install the engine mounting insulator sub-assembly RH with the 4 bolts and 3 nuts.

      Torque:
      for bolt and nut A
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }
      for nut B
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }

    2. Attach the clamp to connect the air conditioner tube and accessory assembly.

    3. Attach the 2 clamps to connect the suction pipe sub-assembly.

    4. Remove the jack.

  6. CONNECT RADIATOR RESERVOIR ASSEMBLY


    1. Connect the radiator reservoir assembly with the 2 bolts.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  7. INSTALL NO. 2 TURBO INSULATOR

    Click here

  8. INSTALL EGR VALVE BRACKET

    Click here

  9. INSTALL EXHAUST MANIFOLD

    Click here

  10. INSTALL CAMSHAFT AND NO. 2 CAMSHAFT

    Click here

  11. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.