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note

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Thoroughly clean all parts to be assembled.

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Always use a new cylinder head and manifold gasket.

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Always use new cylinder head bolts. Cylinder head bolts are torque-to-yield bolts designed to be permanently elongated beyond the state of elasticity when torqued, so if the bolts are removed and reused, it may cause the bolts to break or fail to maintain clamping force.

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The cylinder head gasket is a metal gasket. Be careful not to bend it.

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Rotate the crankshaft, and set the No.1 piston at TDC.

Select the cylinder head gasket.

(1)

Measure the piston protrusion from the upper cylinder block face (I) on 8 places (A ~ H) at T.D.C.

Measure on the crankshaft center line considering the piston migration.

(2)

Select the gasket in the table below using the average value of piston protrusions. If the measured value of any of the points exceeds the limit of certain rank, use the gasket of the next higher rank.

Displacement	1.4 / 1.6
Average of piston protrusion	+0.035mm(0.0014in) ≤ ~ < +0.105mm(0.0041in)	+0.105mm(0.0041in) ≤ ~ < +0.175mm(0.0069in)	+0.175mm(0.0069in) ≤ ~ < +0.245mm(0.0096in)
Uncompressed gasket thickness	1.00 ~ 1.15mm(0.0394 ~ 0.0453in)	1.05 ~ 1.20mm(0.0413 ~ 0.0472in)	1.10 ~ 1.25mm(0.0433 ~ 0.0492in)
Compressed gasket thickness	0.90 ~ 1.00mm(0.354 ~ 0.394in)	0.95 ~ 1.05mm(0.0374 ~ 0.0413in)	1.00 ~ 1.10mm(0.0394 ~ 0.0433in)
Range of each rank	~≤0.14mm(0.0055in)	0.14mm(0.0055in) ≤ ~ < 0.21mm(0.0083in)	0.21mm(0.0083in) ≤ ~
Identification code
Gasket grade	A	B	C

(3)

Install the gasket so that the identification mark faces toward the timing chain side.

Install the cylinder head bolts.

(1)

Do not apply engine oil on the cylinder head bolts.

(2)

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 (4.8~5.2 kgf.m, 34.7~37.6 lb-ft) + (88~92°) + (118~122°)

note

Install the hydraulic lash adjuster (HLA) (A).

(1)

Before installation, the HLA should be held upright so as not to spill diesel oil or attract dust onto HLA.

(2)

Carefully insert the HLA into the cylinder head so as 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 as the ball weighs only several grams.

Installing with engine oil spilt out of the lash adjuster and air in it may cause an abnormal noise.