CYLINDER HEAD GASKET REPLACEMENT [WLT-1, WLT-2]

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Warning
•  Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep speaks and flames away from fuel.
•  Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line Safety Procedures”.

1.  Disconnect the negative battery cable.

2.  Drain the engine coolant. (See COOLING SYSTEM SERVICE WARNINGS [WLT-1, WLT-2, WL-3].)

3.  Remove the intake manifold, air intake pipe and breather chamber. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [WLT-1, WLT-2].)

4.  Remove the injection nozzle. (See INJECTION NOZZLE REMOVAL/INSTALLATION [WLT-1, WLT-2].)

5.  Remove the turbocharger. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [WLT-1, WLT-2].)

6.  Remove the timing belt. (See TIMING BELT REMOVAL/INSTALLATION [WLT-1, WLT-2].)

7.  Remove in the order indicated in the table.

8.  Install in the reverse order of removal.

9.  Adjust the drive belt deflection. (See DRIVE BELT ADJUSTMENT [WLT-1, WLT-2].)

10.  Bleed air in the fuel line. (See AFTER REPAIR PROCEDURE [WLT-1, WLT-2].)

11.  Start the engine and

(1)  Inspect for engine oil, engine coolant, and fuel leakage.
(2)  Inspect the idle speed.

12.  Inspect the compression.

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1
Drive belt
2
Cylinder head cover
(See Cylinder Head Cover Installation Note.)
3
Cylinder head bolt
(See Cylinder Head Bolt Removal Note.)
(See Cylinder Head Bolt Installation Note.)
4
Cylinder head
5
Cylinder head gasket
(See Cylinder Head Gasket Installation Note.)


Cylinder Head Bolt Removal Note

1.  Remove bolts A.

2.  Loosen the cylinder head bolts in two or three steps in the order shown.

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Cylinder Head Gasket Installation 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 Bolt Installation Note

1.  Measure the length of each bolt.

•  If it exceeds the maximum specification, replace the bolt.
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Cylinder head bolt length
Bolt head mark W
Standard length: 101.2—101.8 mm {3.985—4.007 in}
Maximum length: 102.5 mm {4.035 in}
Bolt head mark N
Standard length: 113.2—113.8 mm {4.457—4.480 in}
Maximum length: 114.5 mm {4.508 in}

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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Tighten torque
29 N·m {3.0 kgf·m, 21 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.

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.

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8.  Tighten bolts A.

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


Cylinder Head Cover Installation Note

1.  Apply silicone sealant to the cylinder head as shown.

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2.  Tighten cylinder head cover bolts A and B.

Tightening torque
1.5—2.9 N·m {16—29 kgf·cm, 14—25 in·lbf}
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3.  Tighten the cylinder head cover bolts in the order shown.

Tightening torque
4.9—8.8 N·m {50—90 kgf·cm, 44—78 in·lbf}