Cylinder Head Installation
Special Tools
- EN-45059 Angle Meter
- EN-51140 Crankshaft Fixing Tool
- GE-7872 Magnetic Base Dial Indicator
Equivalent regional tools: Special Tools
Clean all dirt, debris, and coolant from the engine block cylinder head bolt holes. Failure to remove all foreign material may result in damaged threads, improperly tightened fasteners or damage to components.
- Do not use the cylinder head bolts again. Install NEW cylinder head bolts during assembly.
- Do not use any type of sealant on the cylinder head gasket, unless specified.
- The cylinder head gaskets must be installed in the proper direction and position.
Check that the 2 deflectors (1) are installed in the engine block and install 2 NEW deflectors if the deflectors are missing.
- Clean all sealing surfaces.
- Inspect the flatness of the cylinder head and cylinder block sealing surfaces.
- Set the TDC of cylinder 1.
Install the EN-51140 fixing tool (2).
- Install the fixing pin into the engine block bore (1) and tighten the 2 bolts (3).
- NOTE:
For the measurement, the piston has to stay on TDC. Measure the piston projection dimensions at all pistons.
Install the GE-7872 indicator (1).
- Measure the piston projection of the cylinder 1 and the cylinder 4.
Bolt (3) - Remove [2x]
- Remove the EN-51140 fixing tool (2).
Crankshaft Pulley Bolt (1) - Install [4x]
- Rotate the crankshaft 360 degrees, use a pry bar at the 4 crankshaft pulley bolts (1).
- Crankshaft Pulley Bolt (1) - Remove [4x]
Install the EN-51140 fixing tool (2).
- Install the fixing pin into the engine block bore (1) and tighten the 2 bolts (3).
- Measure the piston projection of the cylinder 2 and the cylinder 3.
- NOTE:
The largest piston projection is decisive for the selection of the cylinder head gasket with the corresponding marking. The different between the three max. projection measurements must be no greater than 0.1 mm (0.0039 in).
Select the cylinder head gasket with the correct identification marks (1):
- Piston projection 0.440 - 0.535 mm (0.0173 - 0.0211 in), choose cylinder head gasket with identification mark on Position I, thickness 1.25 mm (0.049 in).
- Piston projection 0.535 - 0.630 mm (0.0211 - 0.0248 in), choose cylinder head gasket with identification mark on Position II, thickness 1.35 mm (0.053 in).
- Piston projection 0.630 - 0.725 mm (0.0248 - 0.0285 in), choose cylinder head gasket with identification mark on Position III, thickness 1.45 mm (0.057 in).
Bolt (3) - Remove [2x]
- Remove the EN-51140 fixing tool (2).
Crankshaft Pulley Bolt (1) - Install [4x]
- Rotate the crankshaft 360 degrees, use a pry bar at the 4 crankshaft pulley bolts (1).
- Crankshaft Pulley Bolt (1) - Remove [4x]
Install the EN-51140 fixing tool (2) to fix the TDC of cylinder 1.
- Install the fixing pin into the engine block bore (1) and tighten the 2 bolts (3).
Cylinder Head Gasket (3) - Install NEW
- Cylinder Head (2) - Install
- Cylinder Head Bolt (1) - Install NEW [10x] - Do NOT tighten.
-
Cylinder Head Bolt - Tighten in sequence
- First Pass: 50 N.m (37 lb ft)
- Second Pass: 90 degrees - Use the special tool: EN-45059 angle meter
- Third Pass: 90 degrees - Use the special tool: EN-45059 angle meter
- Final Pass: 90 degrees - Use the special tool: EN-45059 angle meter
CAUTION:CAUTION: Install the NEW 2 cylinder head outer bolts (1) and tighten in 2 passes:
- First Pass: 20 N.m (15 lb ft)
- Final Pass: 45 degrees - Use the special tool: EN-45059 angle meter
CAUTION:Install the bearing bracket (1).
Ensure that the cylinder head and the cylinder block sealing surfaces are clear of oil, grease and old gasket material.
Ensure the guide sleeves (4) are properly seated in the engine block.