CYLINDER HEAD ASSEMBLY (II) [WLT-1, WLT-2, WL-3]

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1.  Assemble in the order indicated in the table.

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1
Cylinder head gasket
(See Cylinder Head Gasket Assembly Note.)
2
Cylinder head
(See Cylinder Head Assembly Note.)
3
Blind cover
(See Blind Cover Assembly Note.)
4
Water outlet pipe
5
ECT sensor
6
Water temperature sender unit
(See Water Temperature Sender Unit Assembly Note.)
7
Rocker arm
(See Rocker Arm Assembly Note.)
8
Camshaft
9
Camshaft cap
(See Camshaft Cap Assembly Note.)
10
Seal plate
(See Seal Plate Assembly Note.)
11
Camshaft pulley
(See Camshaft Pulley Assembly Note.)


Cylinder Head Gasket Assembly Note

1.  Measure the piston topping of all the cylinders.

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2.  Choose the gasket according to each measured piston topping.

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Cylinder head gasket select table

Piston topping (mm {in})

Cylinder head gasket identification mark
0.205—0.325 {0.081—0.127}
0.265—0.385 {0.105—0.151}
0.325—0.445 {0.128—0.175}

3.  Apply silicone sealant to the cylinder block as shown in the figure.

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Thickness
φ2.0—3.0 mm {0.079—0.118 in}


Cylinder Head Assembly Note

1.  Before installing the cylinder head bolts, inspect their length. (See BOLT INSPECTION [WLT-1, WLT-2, WL-3].)

2.  Apply clean engine oil to the threads and the seat face of each bolt and install them.

3.  Tighten the cylinder head bolts in the order indicated in the figure in several passes.

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Tightening torque
29 N·m {3.0 kgf·m, 2.1 ft·lbf}

4.  Retighten the bolts in the order shown in the figure until all the bolts are tightened to 29 N·m {3.0 kgf·m, 2.1 ft·lbf}.

5.  Put a paint mark on each bolt head.

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6.  Using the marks as a reference, tighten the cylinder head bolts by turning each 90°—105° in the order indicated in Step 3.

7.  Further tighten each bolt by turning another 90°—105° in the order indicated in Step 3.

8.  Tighten the bolts A.

Tightening torque
17.6—19.6 N·m {1.8—1.9 kgf·m, 13—14 ft·lbf}


Blind Cover Assembly Note

1.  Apply silicone sealant to the blind cover as shown in the figure.

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Thickness
φ1.5—2.5 mm {0.059—0.098 in}


Water Temperature Sender Unit Assembly Note

1.  Apply silicone sealant to the thread of the water temperature sender unit as shown in the figure.

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Rocker Arm Assembly Note

1.  If new rocker arm is used, set dimension A as follows.

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Dimension A
0.0—4.0 mm {0.0—0.15 in}


Camshaft Cap Assembly Note

1.  Apply silicone sealant to the front camshaft cap mounting surfaces as indicated in the figure. Avoid getting sealant onto the camshaft journal, camshaft oil seal surface, and camshaft thrust surface.

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2.  Tighten the camshaft cap bolts gradually in three or four steps in the order shown in the figure.

Caution
•  Because there is little camshaft thrust clearance, the camshaft must be held horizontally while it is installed. Otherwise, excessive force will be applied to the thrust area, causing burrs on the thrust receiving area of the cylinder head journal. To avoid this, the following procedure must be observed.
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3.  Apply soapy water along the perimeter of the new oil seal.

4.  Push the oil seal slightly in by hand.

5.   Tap the oil seal lightly into the cylinder head using the SST and a hammer.

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6.  To ensure that the oil seal is installed correctly, measure the distance between the end of the cylinder head and the face of the oil seal.

Camshaft oil seal press-in amount
0.5—1.0 mm {0.02—0.03 in}


Seal Plate Assembly Note

1.  Tighten the seal plate bolts in the order indicated in the figure.

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Camshaft Pulley Assembly Note

1.  Install the camshaft pulley on the camshaft with the knock pin fitted into the hole at the timing mark.

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Timing mark
WL

2.  Hold the camshaft using a wrench on the cast hexagon and tighten the pully lock bolt.

Caution
•  Do not move the camshaft from this position because it can cause the valve and piston to contact each other and damage them.
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