REMOVAL AND INSTALLATION


Pre-removal Operation
  • Engine Oil Draining (Refer to GROUP 12 - On-vehicle Service, Engine Oil Replacement ).
  • Fuel Injector Removal (Refer to GROUP 13E - Fuel Injector ).
  • Common Rail Assembly Removal (Refer to GROUP 13E - Common Rail and Supply Pump ).
  • Turbocharger Assembly and Exhaust Manifold Removal (Refer to GROUP 15 - Exhaust Manifold and Turbocharger ).
  • Timing Belt Rear Cover Removal (Refer to ).

 Post-installation Operation
  • Timing Belt Rear Cover Installation (Refer to ).
  • Turbocharger Assembly and Exhaust Manifold Installation (Refer to GROUP 15 - Exhaust Manifold and Turbocharger ).
  • Common Rail Assembly Installation (Refer to GROUP 13E - Common Rail and Supply Pump ).
  • Fuel Injector Installation (Refer to GROUP 13E - Fuel Injector ).
  • Engine Oil Refilling (Refer to GROUP 12 - On-vehicle Service, Engine Oil Replacement ).




Removal steps


·
 Control wiring harness connection
<<A>>
·
 Power steering oil pump assembly (Refer to GROUP 37 - Power Steering Oil Pump Assembly ).


·
 Oil hose connection (Refer to ).


·
 Radiator upper hose connection (Refer to GROUP 14 - Radiator ).
<<B>>
 >>B<<
 1.
 Cylinder head bolt

>>B<<
 2.
 Cylinder head bolt washer


3.
 Cylinder head assembly

>>A<<
 4.
 Cylinder head gasket

REMOVAL SERVICE POINTS

<<A>> POWER STEERING OIL PUMP ASSEMBLY REMOVAL
1.With the hose installed, remove the power steering oil pump assembly from the bracket.
2.After removing the power steering oil pump assembly, secure it with a cord in the location where the removal and installation of the cylinder head assembly cannot be hindered.

<<B>> CYLINDER HEAD BOLT REMOVAL

caution Provide one punch mark on the head of the cylinder head bolt each time the bolt is tightened. replace the bolt that already has five punch marks (the evidence of having been tightened five times).

Using a 14 mm - 12 points socket wrench, loosen the cylinder head bolt. Loosen each bolt evenly, little by little, by two or three steps.

INSTALLATION SERVICE POINTS

>>A<< CYLINDER HEAD GASKET INSTALLATION
1.
caution Do not allow any foreign materials get into the coolant passages, oil passages and cylinder.
Degrease the cylinder head gasket mounting surface.

2.
caution The thickness of the original cylinder head gasket is selected according to 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 11H - Cylinder Head and Valves ).
When replacing the cylinder head gasket only, confirm the gasket identification tab and rank, and then select a replacement part according to the following table.
Rank
 Thickness of selected gasket (when tightened) mm
 Identification tab
A
 0.95 ± 0.04
 Non-equipped
B
 1.00 ± 0.04
C
 1.05 ± 0.04

>>B<< CYLINDER HEAD BOLT WASHER/CYLINDER HEAD BOLT INSTALLATION

1.
caution Before installing the cylinder head bolt, check the number of punch marks on its head. (the bolt is reusable if it is four or less.) the number of punch marks corresponds to that to times the bolt has been tightened to the plastic area. if the bolt has five punch marks, replace it.
Apply punch mark to the bolt head of the cylinder head bolt.
2.Set the cylinder head bolt washer with its shear droop toward the bolt head.

3.Apply engine oil to the bolt threads and washers.
note Using a 14 mm - 12 points socket wrench.

4.Tighten the bolts to 78 ± 2 N·m in the indicated sequence.
5.Loosen all the bolts completely.
6.Tighten the bolts again to a torque of 29 ± 2 N·m in the indicated sequence. After that, confirm all bolts are reached to the specified torque, and then go to the next process.

7.Make paint marks on each bolt’s head and on the cylinder head.
8.
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.
Turn the bolts 90° in the tightening direction and in the indicated sequence.
9.Give another 90° turn in the tightening direction to each bolt, making sure that the paint mark on the bolt head and that on the cylinder head are on the same line.