For 1990-2009 cars

#### Special Tools

KM-470-B Angular Torque Gage

### Removal Procedure

Caution: Refer to Battery Disconnect Caution in the Preface section.

1. Disconnect the negative battery cable.
2. Remove the engine cover. Refer to Engine Cover Replacement .
3. Remove the charge air system hoses and ducts. Refer to Charge Air Cooler Inlet Pipe and Outlet Pipe Replacement .
4. Remove the accessory belt. Refer to Drive Belt Replacement .
5. Remove the valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement .
6. Remove the timing belt. Refer to Timing Belt Replacement .
7. Remove the fuel pipe-to-common rail between common rail and fuel injection pump. Refer to Fuel Injector Fuel Feed Pipe Replacement .
8. Remove the power steering pump fastener and pull it left side.
9. Remove the engine wiring splice pack tightening bolt.
10. Remove the oil level indicator tube.
11. Remove the radiator upper hose from the thermostat housing.
12. Remove the engine wiring connectors.
13. Remove the turbocharger wheel bearing oil inlet pipe.
14. Remove the turbocharger wheel bearing oil outlet hose.
15. Remove the pre-catalyst tightening clamp from the turbocharger.
16. Remove the cylinder head bolts.
17. Remove the cylinder head assembly with the gasket.
18. Remove the intake manifold and exhaust manifold from cylinder head assembly.

### Cleaning Procedure

1. Clean the cylinder head surface.
2. Clean the engine block surface.
3. Clean the cylinder head bolts.
4. Clean the engine block bolt holes.

### Gasket Selection Procedure

1. Align the TDC of the piston.
2. Clean the cylinder block sealing surface and piston.
3. Measure the piston projection thickness using by dial gage.
4. Repeat the measuring process on the other cylinders and average the measured piston projection values.
5. Choose the cylinder head gasket specifications.

Specification

• | Piston Protrusion 0.194-0.337 mm

| Gasket Thickness 1.1 mm

• | Piston Protrusion 0.337-0.440 mm

| Gasket Thickness 1.2 mm

• | Piston Protrusion 0.440-0.542 mm

| Gasket Thickness 1.3 mm

### Installation Procedure

1. Install the cylinder head assembly with a new gasket.

Notice: Refer to Fastener Notice in the Preface section.

2. Install the cylinder head tightening bolts.

Tighten
Tighten the cylinder head bolts to 65 N·m (47.9 lb ft). Using KM-470-B , tighten the cylinder head bolts another 120 degrees plus 120 degrees.

3. Install the pre-catalyst tightening clamp to the turbocharger.
4. Install the turbocharger wheel bearing oil inlet pipe.

Tighten
Tighten the turbocharger wheel bearing oil inlet pipe bolts to 23 N·m (17 lb ft).

5. Install the engine wiring splice pack tightening bolt.
6. Install the power steering pump fastener.
7. Install the fuel pipe-to-common rail between common rail and fuel injection pump.
8. Install the oil level indicator tube.

Tighten

• | Tighten the engine wiring splice pack tightening bolt to 15 N·m (11.1 lb ft).

• | Tighten the power steering pump bolts to 25 N·m (18.4 lb ft).

• | Tighten the fuel pipe-to-common rail retaining to 20 N·m (14.8 lb in).

• | Tighten the fuel pipe-to-common rail retaining bolt to 10 N·m (88.5 lb in).

• | Tighten the oil level indicator tube bolts to 11 N·m (97.4 lb in).

9. Install the timing belt. Refer to Timing Belt Replacement .
10. Install the valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement .
11. Install the accessory belt. Refer to Drive Belt Replacement .
12. Install the charge air hoses and ducts. Refer to Charge Air Cooler Inlet Pipe and Outlet Pipe Replacement .
13. Install the engine cover. Refer to Engine Cover Replacement .
14. Connect the negative battery cable.