Removing and installing the cylinder head cover of the K4M engine

Removing and Fitting the K4M Engine Cylinder Head Cover

Removing the cylinder head cover

  • Remove the accessory drive belt.
  • Remove the crankshaft pulley.
  • Remove the right-hand engine mounting.
  • Remove the timing belt.
  • Remove the intake silencer.
  • Remove the air filter housing.
  • Remove the throttle body.
  • Remove the intake manifold.
  • Remove the camshaft oil seals on the timing drive side.
  • Remove the ignition coils.
Removing the oil separator and the lifting eye
Fig. 1. Removing the oil separator and the lifting eye: 1 — crankcase ventilation hose; 2 — oil separator; 3 — lifting eye; 4 — cylinder head cover
  1. Disconnect the crankcase ventilation hose 1 (Figure 1) from the oil separator 2.
  2. Unscrew the eight retaining bolts (8 mm socket, extension, handle).
  3. Separate the oil separator 2 from the cylinder head cover 4 (flat-blade screwdriver).
  4. Remove the engine lifting eye 3 on the flywheel side from the cylinder head cover 4 (16 mm socket, ratchet wrench).
Removing the cylinder head cover
Fig. 2. Removing the K4M engine cylinder head cover: 1 — cylinder head cover retaining bolts
  1. Unscrew the cylinder head cover retaining bolts 1 (Figure 2) (8 mm socket, extension, ratchet wrench).
  2. Separate the cylinder head cover by pulling it upwards and tapping on the lugs with a bronze drift (special drift).
  3. Remove the cylinder head cover.

Fitting the cylinder head cover

  1. Clean the cylinder head and the head cover of sealant residues.
  2. Degrease the mating surfaces of the cylinder head and the cylinder head cover (brush, white spirit).
Applying sealant to the cover
Fig. 3. Applying sealant to the K4M engine cylinder head cover
  1. Apply the Mastixo sealant with a paint roller (Figure 3).
  2. Remove the sealant from the working surfaces of the bearings in the cylinder head cover (rag).
  3. Fit the cylinder head cover.
Tightening sequence of the cylinder head cover bolts
Fig. 4. Tightening sequence of the K4M engine cylinder head cover retaining bolts: 1–24 — cylinder head cover retaining bolts
  1. Fit and tighten in the indicated sequence the cylinder head cover retaining bolts 1–24 (Figure 4) in several stages (8 mm socket, extension, torque wrench):
    • stage 1 — bolts 22, 23, 20 and 13 to a torque of 8 N·m (0.8 kgf·m);
    • stage 2 — bolts 1–12, 14–19, 21 and 24 to a torque of 15 N·m (1.5 kgf·m);
    • stage 3 — slacken bolts 22, 23, 20 and 13;
    • stage 4 — tighten bolts 22, 23, 20 and 13 to a torque of 15 N·m (1.5 kgf·m).
  2. Fit the engine lifting eye 3 (Figure 1) on the flywheel side to the cylinder head cover. Retaining bolt tightening torque: 11 N·m (1.1 kgf·m) (16 mm socket, torque wrench).
  3. Clean the oil separator 2 of sealant residues.
  4. Degrease the mating surfaces of the cylinder head cover and the oil separator (brush, white spirit).
Applying sealant to the oil separator
Fig. 5. Applying sealant to the K4M engine oil separator
  1. Apply the Mastixo sealant to the oil separator with a paint roller in accordance with Figure 5.
  2. Fit the oil separator.
Tightening sequence of the oil separator bolts
Fig. 6. Tightening sequence of the K4M engine oil separator retaining bolts: 1–8 — oil separator retaining bolts
  1. Fit and tighten in the indicated sequence the oil separator retaining bolts 1–8 (Figure 6). Oil separator retaining bolt tightening torque: 15 N·m (1.5 kgf·m) (8 mm socket, extension, torque wrench).
  2. Connect the crankcase ventilation hose 1 (Figure 1) to the oil separator 2.
  3. Fit the ignition coils.
  4. Fit the camshaft oil seals.
  5. Fit the intake manifold.
  6. Fit the throttle body.
  7. Fit the air filter housing.
  8. Fit the intake silencer.
  9. Fit the timing belt.
  10. Fit the right-hand engine mounting.
  11. Fit the crankshaft pulley.
  12. Fit the accessory drive belt.