22/4/2019 Cylinder head assembly reassembly (4JK1)

Cylinder head assembly reassembly (4JK1)

1. Oil seal installation

1. Install the oil seal to the cylinder head using special tool.

Note
Install it to the injection pipe insertion surface using the oil seal installer.
Tap the seal so that it is not slanted.

Caution
Be careful not to damage the lip section.

SST: 5-8840-2820-0 - oil seal installer

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22/4/2019 Cylinder head assembly reassembly (4JK1)

1. Cylinder head
2. Oil seal installer

2. Valve guide installation

1. Install the valve guide to the cylinder head using special tool.

Note
Use the valve guide remover and installer to tap the valve guide from the upper surface side of the
cylinder head.

SST: 5-8840-2816-0 - valve guide remover and installer

Caution
When replacing the valve guide, replace as a set with the valve.

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22/4/2019 Cylinder head assembly reassembly (4JK1)

1. The height from the upper surface of the cylinder head to the end surface of the valve guide
2. Cylinder head

Valve stem height： 12.35 to 12.85 mm { 0.4862 to 0.5059 in }

3. Spring lower seat installation

1. Install the spring lower seat to the cylinder head.

4. Valve stem oil seal installation

1. Apply the engine oil to the valve stem oil seal.

Note
Apply it to the outer circumference of the valve guide.

2. Install the valve stem oil seal to the cylinder head using special tool.

Note
Install it using a valve stem seal installer.

SST: 5-8840-2882-0 - valve stem seal installer

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Note
After installing the valve stem oil seal, check that it is securely inserted all the way, that the oil seal
is not inclined, and that the garter spring will not come loose.

5. Exhaust valve installation

1. Apply the engine oil to the exhaust valve.

Note
Apply it to the valve stem portion.

2. Install the exhaust valve to the cylinder head.

6. Inlet valve installation

1. Apply the engine oil to the inlet valve.

Note
Apply it to the valve stem portion.

2. Install the inlet valve to the cylinder head.

7. Valve spring installation

1. Install the valve spring to the cylinder head.

8. Spring upper seat installation

1. Install the spring upper seat to the valve spring.

9. Split collar installation

1. Install the split collar to the valve using special tool.

Note

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Using a valve spring compressor lever and valve spring compressor pivot, compress the valve
springs and install the split collars.

SST: 5-8840-2818-0 - valve spring compressor lever

SST: 5-8840-2819-0 - valve spring compressor pivot

1. Valve spring compressor lever

2. Valve spring compressor pivot

Caution
Move it up and down to confirm that it moves smoothly.

10. Valve stem end cap installation

1. Apply the engine oil to the valve stem end cap.

Note
Apply to the valve stem end and valve stem end cap.

2. Install the valve stem end cap to the valve stem.

11. Exhaust manifold installation

1. Install the gasket to the engine.

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22/4/2019 Cylinder head assembly reassembly (4JK1)

Note
Assemble the projection section to the rear side of the cylinder head.

1. Projection

2. Temporarily tighten the exhaust manifold to the cylinder head.

Note
Install the washer and nut, and tighten them temporarily as shown in the diagram.

1. Stub bolt
2. Washer
3. Nut

3. Securely tighten the exhaust manifold to the cylinder head.

Note
Tighten the 8 nuts according to the order given in the diagram.

Tightening torque： 52 N・m { 5.3 kgf・m / 38 lb・ft }

Caution
Avoid tightening them too much because doing so may hamper expansion and contraction of the
manifold due to heat.
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22/4/2019 Cylinder head assembly reassembly (4JK1)

12. Turbocharger assembly installation

1. Install the gasket to the turbocharger.

2. Install the turbocharger to the exhaust manifold.

Tightening torque： 27 N・m { 2.8 kgf・m / 20 lb・ft }

Note
The following applies to Euro3 and Euro4 specifications

Note
The following applies to specifications other than Euro3 and Euro4

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22/4/2019 Cylinder head assembly reassembly (4JK1)

Note
Feed 0.5 cc engine oil from the oil filler.

13. EGR cooler installation

Note
The following applies to Euro4 specifications

1. Temporarily tighten the EGR cooler to the cylinder head and the exhaust manifold.

Note
Temporarily tighten in the order shown in the diagram.

2. Securely tighten the EGR cooler to the cylinder head and the exhaust manifold.

Note
Firmly tighten in the order shown in the diagram.

Tightening torque： 27 N・m { 2.8 kgf・m / 20 lb・ft }

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Note
The following applies to Euro3 specifications

3. Temporarily tighten the EGR cooler to the cylinder head and the exhaust manifold.

Note
Temporarily tighten in the order shown in the diagram.

4. Securely tighten the EGR cooler to the cylinder head and the exhaust manifold.

Note
Temporarily tighten in the order shown in the diagram.

Tightening torque： 27 N・m { 2.8 kgf・m / 20 lb・ft } 1, 2, 4, 5 in the diagram

Tightening torque： 24 N・m { 2.4 kgf・m / 18 lb・ft } 3 in the diagram

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14. Inlet manifold installation

1. Install the gasket to the inlet manifold.

2. Install the inlet manifold to the cylinder head.

Note
Tighten the nuts and bolts in the order in the diagram.

Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft }

15. EGR valve installation

Note
The following applies to Euro2, Euro3, and Euro4 specifications

1. Install the EGR valve to the inlet manifold.

Tightening torque of the EGR valve

Nut ： 27 N・m { 2.8 kgf・m / 20
lb・ft }
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22/4/2019 Cylinder head assembly reassembly (4JK1)

： 24 N・m { 2.4 kgf・m / 18

Bolt
lb・ft }

16. Rear engine hanger bracket installation

Note
The following applies to specifications other than Euro3 and Euro4

1. Install the rear engine hanger bracket to the cylinder head assembly.

Tightening torque： 51 N・m { 5.2 kgf・m / 38 lb・ft }

17. Front engine hanger installation

1. Install the front engine hanger to the cylinder head assembly.

Tightening torque： 51 N・m { 5.2 kgf・m / 38 lb・ft }

2. Install the rear engine hanger to the cylinder head.

Note
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22/4/2019 Cylinder head assembly reassembly (4JK1)
The following applies to specifications other than Euro2

SST: 5-8840-2861-0 - engine hanger

1. Rear engine hanger

Note
The following applies to Euro2 specifications

SST: 5-8840-2886-0 - rear engine hanger

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Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft }

18. Sprocket installation

1. Install the sprocket to the idle gear D.

Tightening torque： 8 N・m { 0.8 kgf・m / 71 lb・in }

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