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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 toque-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. Take care not to bend it.

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Rotate the crankshaft, 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. Although even the only 1 point is over than the each rank limit, use 1 rank upper gasket than specified in the table below.

Displacement	1.6
Average of piston protrusion	0.035 ~ 0.105mm (0.0014 ~ 0.0041in)	0.105 ~ 0.175mm (0.0041 ~ 0.0069in)	0.175 ~ 0.245mm (0.0069 ~ 0.0096in)
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)
Limit of each rank extent	0.14mm (0.0055in)	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 adjust (HLA) (A).

(1)

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.

(2)

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.