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Stop ! Read this important information before

proceeding any further.

Thank you for purchasing a quality Kiwi Cylinder Heads product. Please read the following information carefully to ensure the installation goes smoothly and the repair is completed effectively. If at anytime you are unsure or just require clarification on fitment, please call us free on either:

0800-549-429 (New Zealand) or 1800-786-987 (Australia)

If the purchaser chooses to fit parts other than those supplied, this does not invalidate the Kiwi Cylinder Heads warranty other than to the extent that the replacement parts carry no warranty unless purchased from Kiwi Cylinder Heads. Additionally, any consequential damage to Kiwi Cylinder Heads products as a result of using these alternative parts is not covered by the Kiwi Cylinder Heads warranty.

IMPORTANT If this product is being fitted as a replacement for an item, which has failed in service? It is critical that the “real cause” of the failure has been identified and rectified. Failure to do so may result in this product also failing for the same reasons, which will not be covered under any warranty.

Kiwi Cylinder Heads Product & Service Range

• New Replacement Bare Cylinder Heads • All New Fully Assembled Cylinder Head Kits • Head Gaskets and Head Sets • Head Bolt Sets • Valve Train Components • Water Pumps • Radiators • Hylift-Johnson Hydraulic and Performance Lifters (US Made) • YD25.com Timing Chain Upgrade Kits • Genuine Parts Sourcing Service • Extensive Workshop Manual information Service • World –Wide Supply

Kiwi Cylinder Heads Ltd (NZ) 31 Carbine Rd, Mt Wellington Auck. 1060. PO Box 132189, Sylvia Park, Auck 1644.

0800-549-429, info@cylinderheads.co.nz, www.cylinderheads.co.nz Kiwi Cylinder Heads Pty Ltd (Australia)

318-326 St Vincent St, Port Adelaide, SA 5015. 1800-786-987, www.cylinderheadsaustralia.com.au, info@cylinderheads.co.nz

 

Part Number: 1002 1210 Hyundai D4EB

!

!Kiw

i Cylinder Heads 12 M

onth, Unlimited Kilom

eter, Parts &

Labor Warranty

This new

cylinder head is subject to a 12 Month (from

date of purchase), unlimited kilom

eter, parts & labor w

arranty. This means in

the rare event this product fails due to either a manufacturing or physical fault the purchaser is covered by this w

arranty for a period of 12 m

onths from date of purchase, and it includes replacem

ent parts & labor at a fair and reasonable rate to re-instate the vehicle to its pre-failure state. This excludes service item

s such as but not limited to, oil, coolant, filters etc. as w

ell as any vehicle recovery costs and the cost of any replacem

ent vehicle. R

esponsibilities: To maintain this w

arranty the product is to be professionally installed & serviced in accordance to the vehicle m

anufacturers guidelines & service intervals. Ensure the vehicle is not used in an inappropriate m

anner for which it is designed or

intended for. To minim

ize any further unnecessary damage once a fault is suspected or detected in the vehicles operation. To contact

the installer or Kiwi C

ylinder Heads Ltd at the very earliest opportunity after detecting or suspecting a fault. P

roof of Purchase &

service records w

ill be requested in an event of a claim. The w

arranty will be voided if the vehicle to w

hich it is fitted is used in off-road, com

petition or modified beyond the vehicle m

anufacturers original design. H

ow to m

ake a claim: If there is a suspected w

arranty fault, Kiw

i Cylinder H

eads Ltd must be contacted before any repair w

ork can com

mence. (C

ontact details below) A w

arranty claim form

and claim num

ber will be m

ade available and must be com

pleted & returned to Kiw

i Cylinder H

eads Ltd, along with any requested related docum

ents and/or parts. The suspected failed parts supplied by Kiwi

Cylinder H

eads Ltd must be returned to a pre-determ

ined location for inspection and analysis of the suspected failure. The cost of returning parts &

documents is the responsibility of the claim

ant. Failure to adhere to these procedures may void any w

arranty.

This warranty does not exclude any rights to the claim

ant under the N.Z C

onsumer G

uarantees Act 1993

or the Australian C

onsumer Law

2011.

Kiw

i Cylinder H

eads Ltd, PO B

ox 132-189 Sylvia Park, Mt W

ellington, Auckland 1644. 0800-549-429, info@

cylinderheads.co.nz K

iwi C

ylinder Heads (Pty) Ltd, 318-326 St Vincent St, Port A

delaide, SA 5015. Ph.1800-786-987, Fax 1800-786-535

             

 

     

                                                                                 

SIX  STEPS  TO  SUCCESS!  TO  ENSURE  A  SUCCESSFUL  INSTALLATION  OF  THIS  CYLINDER  HEAD  

1. ENSURE  BOTH  MATING  SURFACES  ARE  CLEAN  AND  FREE  OF  DIRT  AND  OIL.  

2. DO  NOT  CLEAN  BLOCK  THREADS  WITH  A  THREAD  TAP.  USE  AN  OLD  HEAD  BOLT  WITH  A  CLEANING  GROOVE  CUT  THE  LENGTH  OF  THE  THREAD  TO  THOROUGHLY  CLEAN  BLOCK  THREADS.  

3. MAKE  SURE  NEW  TORQUE  TO  YEILD  HEAD  BOLTS  ARE  ALWAYS  USED.  ENSURE  A  LIGHT  COVERING  OF  ENGINE  OIL  IS  APPLIED  TO  THE  THREADS  AND  UNDER  THE  BOLT  HEAD  AND  WASHER.  

4. ENSURE  THE  CORRECT  TORQUE  SETTINGS  AND  SEQUENCE  IS  EMPLOYED.  

5. MULTI-­‐LAYER  STEEL  (MLS)  HEAD  GASKETS:  FLUSH  BLOCK  OF  ANY  REMAINING  ANTI-­‐FREEZE,  DO  NOT  ADD  ANY  NEW  ANTI-­‐FREEZE  TO  COOLANT  SYSTEM  UNTIL  ENGINE  HAS  TRAVELLED  A  MINIMUM  OF  600KMS.  TO  ENSURE  THE  GASKET  HAS  THE  BEST  POSSIBLE  CHANCE  TO  SEAL  CORRECTLY.  

6. FUEL  INJECTORS  MUST  BE  CHECKED  FOR  CORRECT  OPERATION  AND  SERVICED  IF  REQUIRED.  IF  YOU  HAVE  ANY  QUERIES  PLEASE  CALL  US  

ON  0800-­‐549-­‐429  N.Z  1800-­‐786-­‐987  Australia  

 

           

       

               

                 

                 

               

       

 

 

 

 

 

 

CLEAN SURFACES

USE AN OLD BOLT TO CLEAN THREADS

OIL HEAD BOLTS

CORRECT TORQUE PROCEDURE?

NO ANTI-FREEZE FOR MIN. 600KMS

SERVICE THE INJECTORS

 

 

On  receiving  the  new  cylinder  head  visually  check  for  courier  damage  and  that   it   is   in  all   respects   the  same  as   the  old  head  with   the  same  openings,  threads,  holes  and  bungs.  Check  dowel  hole  depths  

 

 

Check   that   injectors,   sparkplugs,   and   other   fittings,   fit   correctly   in   the  threaded  holes  before  fitting  the  head  to  the  rest  of  the  engine.  

 

 

Check  that  there  are  no  visible  blockages  in  water  ways  and  oil  galleries  and  use  a  compressed  air  gun  to  blow  all  of  these  out  as  debris  can  sometimes  become  trapped  during  the  manufacturing  process.  

 

 

(if   this   is   a   complete   assembled   cylinder   head)   Confirm   all   the  tappet/valve  clearances  are  correct  –  while  they  were  set  at  assembly  it   is  still  worth  checking.  Also  check  tappet  adjusters  are  tight  and  will  not  move  in  service.  Prevention  is  better  than  cure!  

 

 

(if  this  is  a  complete  assembled  cylinder  head)  Ensure  the  camshaft,  cam  followers   and   all   other   moving   parts   are   well   lubricated   with   the  “ZPaste”  supplied  before  attempting  to  turn  the  engine  over.  

 

 

Ensure  all  gasket  surfaces  and  the  cylinder  head  and  block  mating  faces  are  clean,  undamaged,  smooth  and  free  from  oil,  grease  &  water  before  fitting.    This  is  especially  critical  when  using  multi-­‐layer  steel  gaskets.  

 

 

Use   new   head   bolts   and   gaskets   and   tighten   the   bolts   to   manufacturer’s  specifications.    Be  sure  to  oil  the  threads  and  under  side  of  the  bolt  heads  &  washers   before   fitting.   It   may   also   be   best   to   leave   the   head   &   gasket   to  settle   between   each   stage   of   the   tightening   process.  Do   not   clean   block  threads  with  a  tap,  use  an  old  head  bolt  with  a  cleaning  groove  cut  the  length  of  bolt  instead.  

 

 

With   spark   plugs/glow   plugs   &   rocker   cover   removed,   fuel   solinoid  disconnected,   the   engine   should   be   turned   over   until   oil   is   visiablly  flowing  through  all  the  oil  galleries  in  the  cylinder  head.    

 

 

Complete  the  re-­‐assembly  of  the  engine  to  industry  standards  and  test  run  checking   for   any   leaks   (oil   or   water)   after   the   engine   has   reached   full  operating   temperature  but  prior   to  any   road   test.    Be   sure   to  bleed  all   air  from  the  cooling  system  at  this  time.    

 

If   using   a   multi-­‐layer   steel   gasket   it   is   recommended   that   anti-­‐freeze   is  only  added  to  the  cooling  system  after  the  vehicle  has  run  500  –  1000  km  

 

   

 

 

 

 

 

 

 

 

 

 

 

 

 

IF YOU HAVE ANY DOUBTS OR QUERIES CALL US FREE ON 0800-549-429 NZ or 1800-786-987

CYLINDER HEAD INSTALLATION CHECK LIST  

Hyundai(/(Kia(D4EA(CRD(Torque(Sequence(

•  HEAD BOLT P/N QUANTITIES: •  HEAD BOLT TIGHTENING SEQUENCE. •  STEP ONE: 25Nm •  STEP TWO: 50Nm •  STEP THREE: +120 Degrees •  STEP FOUR: +90 Degrees

•  IMPORTANT: ALL BOLT THREADS, BOLTHEADS AND WASHERS MUST BE LIGHTLY OILED. •  USING AN OLD HEADBOLT WITH GROOVE CUT DOWN THREAD, CLEAN THE BLOCK HEADBOLT THREADS.

FRONT(

www.cylinderheads.co.nz((0800C549C429 (www.cylinderheadsaustralia.com.au((1800C786C987(

     

   

Note:   This   cylinder   head   is   only   suitable   for   the   “   8  inlet  port”  model  engines.  As  illustrated  in  the  above  picture.