Hyundai: Engine D4FA. Manual — part 21
CYLINDER HEAD ASSEMBLY
EMA -53
REASSEMBLY
EB6B9E0F
NOTE
• Thoroughly clean all parts to be assembled.
• Before installing the parts, apply fresh engine oil
to all sliding and rotating surface.
• Replace oil seals with new ones.
1.
Install the valves.
1)
Using the SST (09222-2A000)(A), push in a new
stem oil seal.
NOTE
Do not reuse old valve stem oil seals.
Incorrect installation of the seal could result in oil leak-
age past the valve guides.
A
LCGF102A
2)
Install the valve, valve spring and spring retainer.
NOTE
Place the valve springs so that the side coated with
enamel faces toward the valve spring retainer and
then installs the retainer.
3)
Using the SST(09222-2A100, 09222-3K000)(A),
compress the spring and install the retainer locks.
After installing the valves, ensure that the retainer
locks are correctly in place before releasing the
valve spring compressor.
A
LCGF101A
4)
Lightly tap the end of each valve stem two or
three times with the wooden handle of a hammer
to ensure proper seating of the valve and retainer
lock.
EMA -54
ENGINE (D4FA - DSL1.5)
INSTALLATION
EEFE8B3B
NOTE
• Thoroughly clean all parts to be assembled.
• Always use a new cylinder head and manifold
gasket.
• Always use a new cylinder head bolt.
• The cylinder head gasket is a metal gasket. Take
care not to bend it.
• Rotate the crankshaft, set the No.1 piston at TDC.
1.
Cylinder head dowel pins must be aligned.
2.
Select the cylinder head gasket.
1)
Measure the piston protrusion from the upper
cylinder block face (I) on 8 places (A ~ H) at T.D.C.
Measure on the crankshaft center line consider-
ing the piston migration.
A
B
C
D
E
F
G
H
I
ACGF012A
LCGF129A
2)
Select the gasket in the table below using the av-
erage value of piston protrusions. Although even
the only 1 point is over than the each rank limit,
use 1 rank upper gasket than specified in the ta-
ble below.
Identification code
LCGF104A
Displacement
1.5 L
Average of piston protrusion
0.035 ~ 0.105mm
(0.0014 ~ 0.0041in)
0.105 ~ 0.175mm
(0.0041 ~ 0.0069in)
0.175 ~ 0.245mm
(0.0069 ~ 0.0096in)
Gasket thickness
1.00 ~ 1.15mm
(0.0394 ~ 0.0453in)
1.05 ~ 1.20mm
(0.0413 ~ 0.0472in)
1.10 ~ 1.25mm
(0.0433 ~ 0.0492in)
Limit of each rank extant
0.14mm (0.0055in)
0.21mm (0.0083in)
-
Identification code
LCGF130A
LCGF132A
LCGF131A
CYLINDER HEAD ASSEMBLY
EMA -55
3)
Install the gasket so that the identification mark
faces toward the timing chain side.
3.
Install the cylinder head gasket(A) on the cylinder
block.
NOTE
Be careful of the installation direction.
A
ACGF013A
4.
Place the cylinder head (A) quietly in order not to dam-
age the gasket with the bottom part of the end.
A
LCGF050A
5.
Install the cylinder head bolts.
1)
Apply a light coat if engine oil on the threads and
under the heads of the cylinder head bolts.
2)
Using socket (12PT), install and tighten the 10
cylinder head bolts, in several passes, in the se-
quence shown.
Tightening torque :
49.0N.m (5.0kgf.m, 36.2lb-ft)+90 + 120
NOTE
Do not reuse the cylinder head bolts.
8
4
1
5
9
10
6
2
3
7
LCGF153A
6.
Istall the HLA(Hydraulic Lash Adjust)(A).
A
LCGF048A
1)
Until installing HLA shall be held upright so that
diesel oil in HLA should not spill and assured that
dust does not adhere to HLA.
2)
HLA shall be inserted tenderly to the cylinder
head not to spill diesel oil from HLA. In case of
spilling, air bent shall be done in accordance with
the air bent procedure.
EMA -56
ENGINE (D4FA - DSL1.5)
NOTE
Stroke HLA in diesel oil 4~5 times by pushing its cap
while pushing the ball down slightly by hard steel wire.
(Take care not to severely push hard steel wire down
since ball is several grames.)
Steel wire
LCGF133A
7.
Install the cam follower(A).
A
LCGF047A
8.
Install the camshaft(A).
A
LCGF046A
9.
Install the camshaft bearing caps(A).
Tightening torque :
12.7 ~ 13.7N.m (1.3 ~ 1.4kgf.m, 9.4 ~ 10.1lb-ft)
A
LCGF045A
10. Install the vacuum pump(A) with new gasket(B).
Tightening torque :
10.8 ~ 14.7N.m (1.1 ~ 1.5kgf.m, 8.0 ~ 10.8lb-ft)
A
Apply liquid
gasket
B
LCGF154A
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