Replacing cylinder head gasket
1. Make
sure
to note the mark (A) of cylinder head
gasket (1) in advance.
2. Replace the same mark (A) as the original cylinder
head gasket (1).
(1) Cylinder head gasket (A) Mark
Gasket
mark and
code
number
Model
D1803-CR-E4, -TE4, -
TIE4
V2403-CR-E4, -TE4,
TE4BG, -TIE4
15 1G750-03600 1G790-03600
20 1G750-03310 1G790-03310
25 1G750-03610 1G790-03610
30 1G750-03620 1G790-03620
35 1G750-03630 1G790-03630
Selecting cylinder head gasket
1. Measure the
protrusion or recess of the piston head
from the level of crankcase cylinder face at 4 points
(2) per each piston with a dial gauge.
(2) Measuring points
2. Get the average of the measurements.
3. Use
the
below table to select an applicable cylinder
head gasket.
Gasket dimension (Number) Piston protrusion
15
0.475 to 0.525 mm
0.0187 to 0.0206 in.
20
0.525 to 0.575 mm
0.0207 to 0.0226 in.
25
0.575 to 0.625 mm
0.0227 to 0.0246 in.
30
0.625 to 0.675 mm
0.0246 to 0.0265 in.
35
0.675 to 0.725 mm
0.0266 to 0.0285 in.
4.30 Measuring angular deviation
between crankshaft T.D.C. and
crankshaft position sensor detected
T
.D.C.
IMPORTANT
• If the
crankshaft, flywheel housing and/or
flywheel are replaced, it is necessary to
calibrate the injection timing with the diagnosis
tool.
Tools required
• Dial gauge
• Tri-square
• Injection top correction jig
1. Remove the
cylinder head cover, injectors and the
rocker arm (1).
2. Bring the piston of cylinder 4 to T.D.C. for 4
cylinder,or piston of cylinder 1 to T.D.C. for 3
cylinder.
3. Remove the exhaust side valve spring of #4
cylinder (2) or #1 cylinder.
(1) Rocker arm (2) Exhaust side valve spring of
#4 cylinder
4. Insert
a small O-ring (4) to prevent the exhaust
valve (5) from falling into the cylinder
.
4. ENGINE
SERVICING
4. Checking and adjusting
D1803-CR-E4,D1803-CR-TE4,D1803-CR-TIE4,V2403-CR-E4,V2403-CR-TE4,V2403-CR-TE4BG,V2403-CR-TIE4
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