Cylinder gasket replacement for EA888 Generation 3 engines requires strict adherence to process standards, otherwise it is prone to oil leakage, oil burning or insufficient cylinder pressure. Here are the key steps and precautions:
1.
Thoroughly remove the old gasket residue on the contact surface of the cylinder block and cylinder head (metal scraper is prohibited, plastic spatula + chemical cleaner is recommended).
Use a ruler to test the flatness: the deformation of the cylinder head/block should be ≤0.05mm, and it should be grinded or replaced if it exceeds the standard.
2.
Cylinder gasket positioning and orientation
EA888 Generation 3 cylinder gasket is a multi-layer metal structure (usually no distinction between front and back, but alignment of the positioning pins is required).
Ensure that the cylinder gasket oil and waterway holes are perfectly matched with the cylinder block (you can compare the old gasket).
3. Cylinder head bolt treatment
Replace the bolts with new ones (one-time use is required, especially for torque tensioning bolts).
Lubricate the threads: apply a small amount of oil (avoid overdoing it and affecting torque accuracy).
Prohibit the cylinder gasket to be coated with sealant (metal composite gasket is designed for dry installation) The actual installation can be lubricated with engine oil first and then installed. Note that the cylinder block needs to be coated with special sealant.
Precautions after installation:
1. First startup inspection:
Idle for 10 minutes after cold start and observe for coolant/oil leakage.
Make sure there is no abnormal noise or high temperature alarm before road test.
2.Break-in period monitoring:
Avoid high RPM (≤3000rpm) for 500km to allow the gasket to fully adapt to the thermal stress.
Recheck the cylinder head bolt torque after 1000km (some models need to be re-tightened in hot car).