2.
Place the cylinder head (A) quietly in order not to damage the gasket with the bottom part of the end.
Thoroughly clean all parts to be assembled.
Always use a new cylinder head and manifold gasket.
Always use a new cylinder head bolt.
The cylinder head gasket is a metal gasket. Take care not to bend it.
Rotate the crankshaft, set the No.1 piston at TDC.
Install the cylinder head gasket.
(Refer to Cylinder Head Assembly – “Cylinder Head Gasket”)
Place the cylinder head (A) quietly in order not to damage the gasket with the bottom part of the end.
Install the cylinder head bolts.
Do not apply engine oil on the cylinder head bolts.
Using the SST (09221-4A000), install and tighten the 10 cylinder head bolts, in several passes, in the sequence shown.
Tightening torque :
47.1~51.0Nm (4.8~5.2kgf.m, 34.7~37.6lb-ft) + (88~92°) + (118~122°)
Do not reuse the cylinder head bolts.
Install the HLA (Hydraulic Lash Adjust) (A).
Until installing HLA shall be held upright so that diesel oil in HLA should not spill and assured that dust does not adhere to HLA.
HLA should be inserted carefully to the cylinder head not to spill engine oil.
If engine oil has spilled out of the lash adjuster, HLA bleeding should be performed according to the below procedure.
HLA bleeding procedure
Stroke the lash adjuster in engine oil by pushing its cap 4 to 5 times while pushing the ball down slightly using a hard steel wire. Be careful not to give the ball a hard push because the ball weighs just several grams.
If installing with engine oil spilling out of the lash adjuster and air in it, it might make an abnormal noise.
Install the cam follower (A).
Install the glow plug (A) and glow plug plate.
Tightening torque
Glow plug :
15 ~ 20N.m (1.5 ~ 2.0kgf.m, 11 ~ 14lb-ft)
Plate nut :
0.8~1.5N.m (0.08 ~ 0.15kgf.m, 0.6 ~ 1.1lb-ft)
Install in the other parts reverse order of removal.
Refill engine with engine oil.
Refill a radiator and a reservoir tank with engine coolant.
Clean battery posts and cable terminals and assemble.
Inspect for fuel leakage.
After assembling the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for approximately two seconds and fuel line pressurizes.
Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.
Bleed air from the cooling system.
Start engine and let it run until it warms up (until the radiator fan operates 3 or 4 times).
Turn off the engine. Check the level in the radiator, add coolant if needed. This will allow trapped air to be removed from the cooling system.
Put radiator cap on tightly, then run the engine again and check for leaks.
