CYLINDER HEAD GASKET INSTALLATION

CAUTION / NOTICE / HINT

Tech Tips

Perform "Inspection After Repair" after replacing the cylinder head sub-assembly.


PROCEDURE


  1. INSTALL CYLINDER HEAD GASKET


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

    2. B005A1GC02
      *1 Cylinder Head Gasket
      *a Lot No.
      *b 3.0 to 5.0 mm (0.118 to 0.197 in.)
      *c 152.5 mm (6.00 in.)
      *d 38 mm (1.50 in.)
      *e 7.0 to 9.0 mm (0.276 to 0.354 in.)
      *f 5.0 to 7.0 mm (0.197 to 0.276 in.)
      B0057RX Engine Front
      B0059IK Seal Packing Application Area

      Apply a seal packing to a new cylinder head gasket as shown in the illustration.

      Note


      • Remove any oil from the contact surface.

      • Install the cylinder head gasket within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

    3. Place a new cylinder head gasket on the cylinder block sub-assembly surface with the front face of the Lot No. stamp upward.

      Note


      • Remove any oil from the contact surface.

      • Pay attention to the installation direction.

      • Do not damage the cylinder head gasket.

  2. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Tech Tips

    Perform "Inspection After Repair" after replacing the cylinder head sub-assembly.



    1. Clean the cylinder head sub-assembly with solvent.

    2. Place the cylinder head sub-assembly on the cylinder block sub-assembly.

      Note


      • Check and clean the cylinder head set bolts and their installation holes.

      • Make sure that no oil is on the mounting surface of the cylinder head sub-assembly.

      • Gently place the cylinder head sub-assembly in order not to damage the cylinder head gasket.

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

    4. Install the 10 cylinder head set plate washers to the 10 cylinder head set bolts.

      Note


      • Install the cylinder head set bolt to the same place it was removed from.

      • Be careful not to drop the cylinder head set plate washers into the cylinder head sub-assembly.

    5. Step 1:


      1. B005AV2N04

        Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 10 cylinder head set bolts in several steps, in the sequence shown in the illustration.

        Torque:
        85 N*m  { 867 kgf*cm, 63 ft.*lbf }

    6. Step 2:


      1. Mark the front side of each cylinder head set bolt head with paint.

      2. Tighten the cylinder head set bolts an additional 90°.

    7. Step 3:


      1. Tighten the cylinder head set bolts an additional 90°.

      2. Check that the paint marks are now at a 180° angle to the front.

        Note

        After installing the cylinder head sub-assembly, wipe off any excess seal packing within 5 minutes.

  3. INSTALL VALVE STEM CAP

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  4. INSTALL VALVE LASH ADJUSTER ASSEMBLY

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  5. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

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  6. CONNECT NO. 7 WATER BY-PASS HOSE


    1. Connect the No. 7 water by-pass hose to the cylinder head sub-assembly, and slide the clamp to secure the hose.

  7. INSTALL NO. 3 WATER BY-PASS PIPE

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  8. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

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  9. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

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  10. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

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  11. ADD ENGINE OIL

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  12. INSTALL NO. 1 CHAIN VIBRATION DAMPER

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  13. INSTALL CHAIN SUB-ASSEMBLY

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  14. INSTALL CHAIN TENSIONER SLIPPER

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  15. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

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  16. INSTALL TIMING CHAIN GUIDE

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  17. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION

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  18. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

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  19. INSTALL VACUUM PUMP ASSEMBLY

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  20. INSTALL TURBOCHARGER SUB-ASSEMBLY

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  21. CONNECT TURBO OIL INLET PIPE SUB-ASSEMBLY

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  22. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

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  23. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

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  24. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

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  25. INSTALL FUEL INJECTOR SEAL (for Direct Injection)

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  26. INSTALL FUEL INJECTOR SET (for Direct Injection)

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  27. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY (for Direct Injection)

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  28. INSTALL FUEL INJECTOR ASSEMBLY (for Port Injection)

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  29. INSTALL FUEL DELIVERY PIPE (for Port Injection)

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  30. INSTALL INTAKE MANIFOLD WITH INTERCOOLER ASSEMBLY AND THROTTLE WITH MOTOR BODY ASSEMBLY

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  31. INSTALL PURGE VSV

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  32. INSTALL NO. 2 WATER BY-PASS PIPE

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  33. INSTALL TIMING CHAIN COVER ASSEMBLY

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