Cylinder Head Installation

CYLINDER HEAD INSTALLATION (SOHC)

Tools Required:
- SA91101NE Feeler Gage Set
- SA9140E Torque Angle Gage
- SA9177NE Straight Edge
- SA9179NE Dial Indicator






1. Remove the gasket material:
a. Using a plastic or wood gasket scraper, remove all the gasket material from the cylinder block surface.
b. Clean the cylinder block bolt holes of any residual sealer, oil, or foreign material. Remove any oil with solvent.
c. Clean the cylinder head bolt threads with a wire brush.
d. Coat the bolt threads with engine oil.






2. Inspect the top of the cylinder block for flatness. Using a SA9177NE or equivalent and a SA91101NE or equivalent, measure the surfaces contacting the cylinder head gasket for warpage.

MAXIMUM TRANSVERSE WARPAGE
- Standard: 0.024 mm (0.0009 in)
- Service Limit: 0.05 mm (0.002 in) max

MAXIMUM LONGITUDINAL WARPAGE
- Standard: 0.08 mm (0.0031 in)
- Service Limit: 0.1 mm (0.004 in) max






3. Inspect liner height at 4 locations around the cylinder bore using a SA9179NE or equivalent.

MAXIMUM INSTALLED LINER HEIGHT/DEPTH
- Standard: Flush
- Service Limit: 0.013 mm (0.0005 in.) max.






4. Inspect the cylinder bore and the tops of the pistons for debris, deep scratches, excessive carbon built up, etc.

NOTICE: The dowel pin end of the camshaft must be located at the 12 o'clock position during installation to prevent valve and piston damage.

5. Viewing from the accessory drive belt and position the number one cylinder at 90 degrees past top dead center (TDC) clockwise. The crankshaft is correctly positioned when the crankshaft key way and sprocket timing mark are aligned with the cylinder block main bearing cap split line.

IMPORTANT: Whenever a cylinder block or the head bolts are replaced, install the cylinder head and torque the bolts to 65 Nm (48 lb ft). Next, remove the bolts, coat the threads with engine oil and follow the torque angle procedure steps. Torquing the bolts one time prior to following the torque angle steps will make sure proper clamp load is achieved.






6. Install a new cylinder head gasket.
7. Install the cylinder head, aligning it on the dowels:
a. Carefully guide the head into place.
b. Thread the bolts, threads coated with engine oil, in by hand until finger tight.

IMPORTANT: The following steps must be completed in sequence. This will ensure uniform bolt tension.






8. Cylinder head bolt tightening procedure:
9. In sequence, torque the cylinder head bolts.

TIGHTEN
Cylinder head bolts - first pass to 30 Nm (22 lb ft).

10. In sequence, torque all bolts.

TIGHTEN
Cylinder head bolts - second pass (SOHC) to 45 Nm (33 lb ft).

11. Install the SA9140E or equivalent, Snap-On Tool 360 or equivalent.
12. Calibrate the gage to zero.
13. In sequence, turn each bolt an additional 90 degrees - final pass.