Contents: Removal ⤓ Removal the camshaft sprocket ⤓ Removal the power steering pump…⤓ Removal the cylinder head ⤓ Installing the cylinder head gasket ⤓ Installing a high pressure fuel hose ⤓ Connecting the Upper Radiator Hose ⤓ Installing the camshaft sprocket ⤓
Removal
Relieve residual pressure from the high pressure fuel line.
Drain the coolant.
Drain the engine oil.
Remove the air filter assembly.
Disconnect the accelerator pedal cable.
Remove the exhaust manifold.
Remove the upper timing belt cover.
Remove the cooling system inlet pipe and thermostat housing assembly.
Remove the cylinder head cover.
Removal the camshaft sprocket
Turn the crankshaft clockwise until the timing marks on the camshaft sprocket and crankshaft sprocket align with the corresponding timing marks, and set the piston of cylinder No.1 to TDC of the compression stroke.
Caution! Turn the crankshaft clockwise only.
Remove the plug and screw the special rod into the hole of the attachment bracket so that it rests against the groove on the tensioner lever.
Slowly screw in the special rod, aligning hole "B" on the automatic tensioner body with hole "A" on the tensioner rod.
Attention! Screw in the special rod with a step of no more than 30° per second. If the rod is screwed in at full speed, it may become deformed due to the difficult movement of the tensioner rod.
Using a strap or wire, secure the timing belt to the camshaft sprocket in the position shown in the figure.
Secure the camshaft sprocket from turning using a special holder and bolts.
Loosen the camshaft sprocket mounting bolt.
Caution: Do not rotate the crankshaft after removing the camshaft sprocket.
Before removing, mark the original position of the radiator hose and clamp. Disconnect the upper radiator hose.
On 4G69 series engines, remove the high pressure fuel hose bracket before disconnecting it.
Remove the fuel hose clamp and pull it in the direction shown by the arrow in the figure.
Note: If the high pressure hose retainer has been released, reinstall it after disconnecting the hose.
Removal the power steering pump assembly with bracket
Remove the power steering pump assembly with the bracket and the hoses connected to it.
Note: Tie the removed power steering pump assembly with bracket and hoses with wire and place it in a place where it will not interfere with the removal and installation of the cylinder head assembly.
Removal the cylinder head
Loosen the bolts in 2 or 3 steps in the sequence shown in the figure, and then remove the cylinder head assembly.
Caution: When loosening the cylinder head bolts, be careful not to damage or deform the spark plug guide tubes, as they are not supplied separately.
Installing the cylinder head gasket
Using a special scraper, remove the remains of the old cylinder head gasket from the cylinder block.
Caution: When performing this operation, do not allow gasket material or other foreign particles to enter the cooling system and lubrication system channels.
Degrease the mating surfaces of the gasket.
When installing, check that all holes on the gasket and cylinder head match.
Make sure the new cylinder head gasket has the correct identification mark for this engine.
Place the cylinder head gasket on the cylinder block with the identification mark facing up so that it is located on the exhaust valve side.
When installing the cylinder head bolts, make sure that the length "A" of each bolt is within the allowable value. If the length "A" exceeds the maximum allowable value, the bolts must be replaced.
Maximum permissible value "A": 99.4 mm.
Apply a thin layer of engine oil to the threads and washers of the cylinder head bolts.
Note: If the cylinder head bolt washer has been replaced, install it with the chamfered side facing up as shown in the illustration.
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Tighten the bolts according to the procedure below.
Note: Always tighten the bolt at an angle exactly equal to 90°. Otherwise, the cylinder head mounting bolt may become loose (the reliability of the gas joint will not be ensured).
Note: If the bolt is turned to an angle greater than 90°, it is necessary to completely loosen it and repeat all operations, starting from point 1.
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Installing a high pressure fuel hose
Lubricate the O-ring with a small amount of fresh engine oil.
Caution! Do not allow oil to enter the fuel manifold.
While slightly turning the flange of the fuel hose to the right and left, carefully insert it into the fuel manifold to avoid damaging the gasket. After installation, check that the hose rotates smoothly in the fuel manifold.
If the hose flange jams when turning, damage to the O-ring gasket may occur. Disconnect the flange (complete with hose) from the fuel manifold and check the gasket for any damage, then insert it back and check for smooth turning.
Connecting the Upper Radiator Hose
When connecting the upper radiator hose, push it onto the protrusion of the pipe until it stops, then tighten the clamp.
The hose clamp should always be installed in the same position as it was installed when removed. Therefore, before installing the clamp, align the alignment marks on the hose clamp and the radiator hose, then connect it.
Installing the camshaft sprocket
Secure the camshaft sprocket from turning using a special fork holder and special bolts.
Tighten the camshaft sprocket mounting bolt to the specified torque.
Tightening torque: 89±9 Nm.
After completing the installation of the parts, perform the following operations:
On 4G69 series engines, install the cylinder head cover.
Install the coolant inlet pipe and thermostat housing assembly.
Install the upper timing belt cover.
Install the exhaust manifold.
On 4G69 series engines, connect the accelerator pedal cable.
Install the air filter assembly.
Fill with coolant and engine oil.
Adjust the tension of the attachment drive belt.
Adjust the accelerator pedal cable.