Remove
- 1. Raise vehicle to suitable working height
- 2. Remove splash panel from vehicle, right side • Remove 2x bolt (1) • Remove 4x clip (2)
- 3. Apply 2x match mark to crankshaft pulley, 120° offset from the No.1 Cylinder top dead centre mark on compression stroke
- 4. Lower vehicle
- 5. Release air cleaner assembly (1) from cylinder head cover • Pull off to release 2x rubber locator
- 6. Remove cover and air cleaner element from air cleaner assembly • Release 2x clip (2), 2x locator
- 7. Disconnect 3x harness connector from 3x ignition coil module (2)
- 8. Remove 3x ignition coil module from 3x spark plug • Remove 3x bolt (1)
- 9. Remove 3x spark plug from cylinder head • Use Spark Plug Wrench KM-194-E
- 10. Remove engine vent valve (2) from cylinder head cover • Pull out • Install new blanking plug
- 11. Remove dipstick from engine
- 12. Release harness from cylinder head cover • Release 2x clip
- 13. Remove breather pipe (1) from cylinder head cover • Release clip
- 14. Remove 2x harness bracket from cylinder head cover • Remove 2x bolt
- 15. Remove cylinder head cover (1) from cylinder head
- 16. Remove 3x gasket from cylinder head cover • Remove 5x bolt (2), in stages, in sequence shown
- 17. Rotate crankshaft clockwise until notch (4) on crankshaft aligns with '0' timing mark (3) on timing chain cover, with No. 1 piston at top dead centre on compression stroke
- 18. Ensure that 2x match mark (1, 2) on 2x camshaft sprocket align with cylinder head surface
Note. Ensure valves on No.1 cylinder are fully closed.
- 19. Clean mating surface of cylinder head and cylinder head cover
- 20. Apply silicon sealant to mating surface of timing chain cover (1) and cylinder head (2) – see “Sealants, Adhesives and Lubricants”
- 21. Install new gasket to cylinder head cover (1)
- 22. Install 3x gasket to cylinder head cover
- 23. Install cylinder head cover to cylinder head • Install 5x bolt (2), do not tighten at this stage • Secure 5x bolt 5 Nm in sequence shown • Secure 5x bolt 8 Nm in sequence shown • Secure 5x bolt 11 Nm in sequence shown
- 24. Install 2x harness bracket to cylinder head cover • Install 2x bolt
- 25. Install breather pipe to cylinder head cover • Secure clip
- 26. Secure harness to cylinder head cover • Secure 2x clip
- 27. Install engine vent valve to cylinder head cover • Remove blanking plug • Push on
- 28. Remove oil filler cap
- 29. Remove cap from coolant expansion tank
Important. Crankshaft must not turn during checking procedure. To ensure crankshaft does not turn, engage first gear and apply parking brake.
- 30. Install adaptor (1) of commercially available pressure loss equipment to cylinder No.1 • Hand tighten adaptor • Follow manufacturers instructions
- 31. Install and connect pressure loss tool (2) to adaptor (1)
- 32. Regulate pressure to 100 psi ( 6.9 bar ), then read off pressure loss
Note. Investigate any acoustically perceivable escape of compressed air from intake manifold, exhaust, spark plug, crankcase and any formation of bubbles in coolant expansion tank. Maximum permissible pressure loss difference between individual cylinders approximately 10%. Maximum pressure loss of one cylinder should not exceed 25%.
- 33. Remove and disconnect pressure loss tool (2) from adaptor (1)
- 34. Remove adaptor (1) from cylinder No.1
- 35. Disengage first gear
Important. Crankshaft must not turn during checking procedure. To ensure crankshaft does not turn, engage first gear and apply parking brake.
- 36. Rotate crankshaft clockwise 240° until cylinder No.3 piston is at (TDC) on compression stroke
- 37. Install adaptor (1) of commercially available pressure loss equipment to cylinder No.3 • Hand tighten adaptor • Follow manufacturers instructions
- 38. Install and connect pressure loss tool (2) to adaptor (1)
- 39. Regulate pressure to 100 psi (6.9 bar) , then read off pressure loss
Note. Investigate any acoustically perceivable escape of compressed air from intake manifold, exhaust, spark plug, crankcase and any formation of bubbles in coolant expansion tank. Maximum permissible pressure loss difference between individual cylinders approximately 10%. Maximum pressure loss of one cylinder should not exceed 25%.
- 40. Remove and disconnect pressure loss tool (2) from adaptor (1)
- 41. Remove adaptor (1) from cylinder No.3
- 42. Disengage first gear
Important. Crankshaft must not turn during checking procedure. To ensure crankshaft does not turn, engage first gear and apply parking brake.
- 43. Rotate crankshaft clockwise 240° till cylinder No.2 piston is at (TDC) on compression stroke
- 44. Install adaptor (1) of commercially available pressure loss equipment to cylinder No.2 • Hand tighten adaptor • Follow manufacturers instructions
- 45. Install and connect pressure loss tool (2) to adaptor (1)
- 46. Regulate pressure to 100 psi (6.9 bar) , then read off pressure loss
Note. Investigate any acoustically perceivable escape of compressed air from intake manifold, exhaust, spark plug, crankcase and any formation of bubbles in coolant expansion tank. Maximum permissible pressure loss difference between individual cylinders approximately 10%. Maximum pressure loss of one cylinder should not exceed 25%.
- 47. Remove and disconnect pressure loss tool (2) from adaptor (1)
- 48. Remove adaptor (1) from cylinder No.2
- 49. Disengage first gear
Install
- 50. Install dipstick to engine
- 51. Install oil filler cap
- 52. Install cap to coolant expansion tank
- 53. Connect 3x harness connector to 3x ignition coil module (2), then secure 3x bolt (1)
- 54. Install air cleaner element and cover to air cleaner assembly (1) • Secure cover to air cleaner assembly – Secure 2x locator, then secure 2x clip (2)
- 55. Secure air cleaner assembly to cylinder head cover • Push on to secure 2x rubber locator
- 56. Raise vehicle
- 57. Install splash panel to vehicle, right side • Install 4x clip (2) • Install 2x bolt (1)