CYLINDER HEAD/CYLINDER BLOCK

ENGINE HOUSINGKYRON SM - 2005.09

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CYLINDER HEAD

Cylinder head bolt

CYLINDER HEAD/CYLINDER BLOCK

Oil Return Check Valve

Cylinder head boltD20DT D27DT

Oil Return Check Valve

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Exhaust manifold

System Characteristics1. 4-valve DOHC valve mechanism

2. Swirl and tangential port

3. 4-bolt type cylinder head bolt

4. Water jacket integrated casting

5. Integrated chain housing and cylinder head

6. Oil gallery: drilled and sealing with cap and screw plug

D27DTD20DT

Intake manifoldIntake manifold

Exhaust manifold


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Height “A” (cylinder head parting surface - cylinder head cover parting surface)

Minimum height after machining

Flatness

Permissible variation of parallelism of top parting surface to bottom in longitu-

dinal direction

Peak-to-valley height

Valve recess “a”

Specifications

In longitudinal direction

In transverse direction

Intake valve

Exhaust valve

140.9 ~ 141.1 mm

140.9 mm

0.075 mm

0.075 mm

within 0.1 mm

0.004 mm

0.74 ~ 0.86 mm

-0.15 ~ 0.15 mm

Cylinder Head Mating Surface Check

Cylinder Head Pressure Leakage TestPreceding Works:

1. Removal of cylinders

2. Removal of intake and exhaust manifold

3. Removal of valves

Test Procedures

1. Place the pressure plate on a flat-bed work bench.

2. Install the cylinder head on the pressure plate.

3. Immerse the cylinder head with the pressure plateinto warm water (approx. 60°C) and pressurize withcompressed air to 2 bar.

Tightening torque 60 Nm

• Examine the cylinder head for air bubbling. If theair bubbles are seen, replace the cylinder head.

NOTICE

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Measurement

1. Measure the cylinder head height “A”.

2. Insert the valves into the valve guides and measurethe recesses.

Limit Over 140.9 mm

Valve recess “a” Intake Valve 0.74 ~ 0.86

Exhaust Valve -0.15 ~ 0.15

• If the height is less than the limit, the cylinderhead must be replaced.

NOTICE

• If the measured value is out of the specifiedrange, machine the valve seat as much as nec-essary until the specified value is achieved.

NOTICE

D27DTD20DT

D27DTD20DT


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Cylinder Head

D20DT Engine

1. Disassembly

Preceding Works:

1. Disconnect the negative battery cable.

2. Apply the parking brake and place the chocks underthe tires. (transmission “N” position)

1. Remove the EGR pipe.

2. Disconnect the injector fuel lines, connector andpreglow plug connector. Remove the cylinder headcover.

3. Rotate the crankshaft pulley to align the OT marks.

1) Align the mark (notch) on sprocket for cylinderNo.1 (exhaust) and for cylinder No.6 (intake).

(align the cylinder No.1 OT)

Disassembly

• Cover the openings of fuel line with the protectivecaps.

CAUTION

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4. Mark on the timing chain, intake camshaft sprocketand exhaust camshaft sprocket for timing settingduring installation.

5. Remove the chain tensioner after removing the EGRpipe and oil dipstick.

6. Remove the high pressure pump and mark on thehigh pressure pump sprocket.

7. Remove the camshaft position sensor.


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8. Hold the camshafts and remove the intake camshaftsprocket and exhaust camshaft sprocket.

9. Remove the upper guide rail with a sliding hammer.

10. Remove the oil cooler and the intake manifold.

11. Remove the cylinder head bolts according to thenumerical sequence.

1) M8 x 25: 2EA

2) M8 x 50: 2EA

3) M12 x 177: 9EA

4) M12 x 158: 1EA (vacuum pump side)

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12. Remove the cylinder head.

Standard 0.765 ~ 1.055 mm

• Inspect the cylinder head mating surface.

• Store the removed injectors and glow plugs so thatthey will not be damaged.

• If there is a sign of oil leakage on the cylinder headgasket, replace it with new one.

CAUTION

13. Measure the piston protrusion from the matingsurface.


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2. Install the cylinder head with the steel gasket.

3. Tighten the cylinder head bolts to specified torqueand torque angle.

1. Measure the length of cylinder head bolts.

1) If the maximum length is exceeded by 2 mm,replace the cylinder head bolt.

Reassembly

• Make sure to place the “TOP” mark upward.

NOTICE

• Apply the oil on the bolt thread when installing.

• Always insert new washer first.

• The bolts at vacuum pump side are shorter than others.

NOTICE

4. Pull the timing chain over the cylinder head and installthe upper guide rail.

• Make sure that the convex surface of upper guiderail faces to front side

• Be careful not to alter the timing point of high pres-sure pump.

NOTICE

Tightening torque

Step 1: 20 ± 2.0 Nm

Step 2: 85 ± 5.0 Nm

Step 3: 360° (120° x 3) + 10°

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5. Install the intake and exhaust camshaft sprocketsand the timing chain.

1) Make sure that the upper guide rail is installedwith proper direction.

2) Make sure that the timing chain is securelyseated on the guide rails.

6. Install the chain tensioner.

Tightening torque 25 Nm + 90°

Tightening torque 65 ± 5.0 Nm

• If the sprocket bolt is stretched over 0.9 mm, re-place it with new one.

• Always install the intake camshaft sprocket first.

NOTICE

• Make sure that the markings on camshaft sprocketand timing chain are aligned.

NOTICE

• Make sure that the EGR steel gasket is properlyinstalled.

NOTICE


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7. Rotate the crankshaft pulley two revolutions andensure that the OT mark on the crankshaft pulleyand the OT mark on the camshaft pulley are aligned.

8. Install the cylinder head cover and the high pressurepump housing.

9. Remove the protective caps from the injector andinstall the new fuel supply pipes.

• If the markings are not aligned, reinstall the cylin-der head.

NOTICE

• Apply the sealant on the bolt threads when install-ing the high pressure pump.

NOTICE

• The fuel pipes are not reusable to keep the clean-ness and parts damage.

NOTICE

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T3. Mark on the intake camshaft sprocket and exhaust

camshaft sprocket for timing setting duringinstallation.

2. Remove the camshaft position sensor.

Installation Notice• The intake manifold can be interfered by the

sensor when installing.

Preceding Works:1. Removal of fan belt

2. Removal of fuel supply and return lines

3. Removal of EGR related pipes and oil dipstick tube

4. Removal of intake manifold mounting bracket

5. Removal of injector fuel line and connector, andglow plug connector

1. Remove the cylinder head cover.

• Plug the openings of injector holes and common railwith the protective caps.

NOTICE

Disassembly

D27DT Engine


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5. Hold the camshafts and remove the intake camshaftsprocket and exhaust camshaft sprocket.

4. Remove the chain tensioner.

6. Pull out the lock pins with a sliding hammer andremove the upper guide rail.

7. Remove the oil cooler, then remove the intakemanifold.

Installation Notice

• The intake manifold can be interfered by thecylinder head bolt (M8 x 50).

• Correctly align the electronic control module onto theshift plate by using two central pins when installing.

NOTICE

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10. Remove the cylinder head.

11. Measure the piston protrusion from the matingsurface.

9. Measure the length of cylinder head bolts.

Installation Notice

• If the maximum length is exceeded by 2 mm,replace the cylinder head bolt.

8. Remove the cylinder head bolts according to thenumerical sequence.

1) M8 x 25: 2 EA

2) M8 x 50: 2 EA

3) M12 x 177: 11 EA

4) M12 x 158: 1 EA (Vacuum pump side)

Length when new

177 mm

158 mm

Maximum Limit

179 mm

160 mm

Standard 0.765 ~ 1.055 mm

• Inspect the cylinder head surface.

• Store the removed injectors and glow plugs so thatthey will not be damaged.

NOTICE


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1. Install the cylinder head with the steel gasket.

2. Tighten the cylinder head bolts to specified torqueand torque angle.

Installation Notice

3. Install the HLA device and finger follower. Check theHLA device with the diagnosis procedures beforeinstallation.

4. Tighten the camshaft bearing cap bolts.

1) Intake: #8, #9, #11

2) Exhaust: #2, #3, #5

• Apply the oil on the bolt thread when installing.• Always insert new washer first.• The bolts (11) at vacuum pump side are

shorter than others.

• Make sure to place the “TOP” mark upward.

NOTICE

• Put the cylinder head on the locating pins.

NOTICE

Reassembly

Tightening torque

Step 1 20 ± 2.0 Nm

Step 2 85 ± 5.0 Nm

Step 3 270° (90° x 3) + 10°

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3) Intake: #7, #10, #12

4) Exhaust: #1, #4, #6

Installation Notice


5. Install the intake and exhaust camshaft sprocketsand the timing chain.

Installation Notice

Tightening torque 25 Nm + 90°

6. Rotate the crankshaft pulley two revolutions andensure that the OT mark on the crankshaft pulleyand the OT mark on the camshaft pulley are aligned.

7. Place the bearing cap with the OT marks on bothcamshafts facing upward.

• Check the finger follower positions and alignif needed.

• If the sprocket bolt is stretched over 0.9 mm,replace it with new one.

• Always install the intake camshaft sprocket first.• Ensure that the markings on camshaft sprocket

and timing chain are aligned.• Make sure that the timing chain is securely

seated on the guide rail.

Intake

Exhaust

• If the markings are not aligned, reinstall the cylin-der head.

NOTICE

• Apply the sealant on the cap (#12) for the vacuumpump when installing.

• Apply the oil on the bearing journals beforeinstallation.

NOTICE


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8. Fit the timing chain onto the camshaft sprocketsand install the upper guide rail.

Install the clamping guide rail pin.

9. Tighten the intake and exhaust camshaft sprocketbolts.

Installation Notice

10. Install the camshaft position sensor.

11. Apply the Loctite to the bolt and tighten it.

Installation Notice


12. Check the intake camshaft before installing thevacuum pump.

13. Install the intake manifold. Install the oil cooler withnew gasket.

Installation Notice

Tightening torque25 ± 2.5 Nm,

90° + 10°

• Ensure that there is no leaks around the coolantline for #1 cylinder


• Install the guide rail with slanted side facingforward.

• Be careful not to change the timing of HP pumpwhen fitting the timing chain.

NOTICE

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14. Install the chain tensioner.

Installation Notice

17. Tighten the cylinder head cover bolts.

Installation Notice

• Apply the sealant to the bolts for the vacuumpump and the timing chain cover.

15. Install the cylinder head cover assembly.

16. Install the rubber gasket.

18. Check the mating surface of the #12 bearing capand the cylinder head for contacting.

19. Check if the O-ring is installed in the vacuum pump.

20. Install the vacuum pump with the key groove aligned.

21. Tighten the vacuum pump mounting bolts.

Installation Notice

Tightening torque 65 ± 5 Nm




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22. Install the PCV valve assembly on the cylinder head.

Installation Notice

24. Remove the protective caps and install the new fuelsupply pipes.

23. Engage the engine oil hose and the PCV valve hose.


• To keep the cleanness and protect the components,the fuel pipes should be replaced with new ones.

• Be careful not to be mixed the fuel pipes becausethe pipe appearance of #1 and #3 cylinders and #2and #4 are same each other.

NOTICE

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1. Remove the cylinder head assembly.

Intake/Exhaust-Removal/Installation

2. Install the removed cylinder head on the assemblyboard (special tool) and set the supporting bar andlever (special tool) on the cylinder head.

3. Push the valve spring seat down with the lever andremove the valve cotter, valve seat and valve spring.

D27DTD20DT


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4. Remove the valves from the cylinder head.

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TY99220082B

Supporting bar and lever

Y99220162B

Guide pin extractor

Y99220112B

Intake manifold guide pin

Special Tools and Equipment

Name and Part Number Application

Y99220092B

Compression pressure measuringadapter and gauge

CYLINDER HEAD/CYLINDER BLOCK

Documents

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