Note.
- 1. Thoroughly clean all surfaces before installation.
- 2. Always use new gaskets.
- 3. Metal cylinder head gasket. Be careful not to bend it.
- 4. Turn the crankshaft to set the piston of the first cylinder to the top dead center position.
1. Install gasket (A) to the cylinder block.
2. Be careful not to damage the gasket, install the cylinder head.
3. Insert washers and apply engine oil to the cylinder head bolts.
4. To gain, and then to tighten bolts of fastening of a head of the block of cylinders in the order specified in drawing in several stages.
Tightening torques for the cylinder head bolts:
- M10: 25 Nm + (60° - 65°) + (60° - 65°);
- M12: 30 Nm + (60° - 65°) + (60° - 65°).
5. Install the phase shifter metering filter (A). Filter tightening torque: 41-51 Nm.
Note. Always use a new phase shifter metering filter gasket and clean the filter each time it is removed.
6. Install the phase shifter dispenser (A). Tightening torque of the phase shifter: 10-12 Nm.
7. Install the chain on the camshafts in such a way that the chain links marked with paint coincide with the alignment marks on the camshaft sprockets (as it shown on the picture).
8. Install camshafts (A) into the cylinder head. Install the camshaft bearing caps (IN) and tighten the mounting bolts to a torque of 14-15 Nm.
9. Install the camshaft chain tensioner (A). Remove retainer (IN).
10. Check and adjust valve clearance.
11. Using a special tool (09221-21000), press in the camshaft seals.
12. Install the camshaft drive gear.
13. Install the drive belt.
14. Install the cylinder head cover.
15. Install gasket (A) into the recess of the cylinder head (IN).
Note:
- Thoroughly clean the gasket and head recess before installation.
- During installation, make sure that the gasket is installed without protruding parts.
16. Apply sealant to the corners of the cut.
Note. Use sealants no. 5699. Before applying the sealant, make sure that the surfaces to be applied are dry and clean. After assembly, wait at least 30 minutes and only then pour engine oil into the engine.
17. Install cylinder head cover (A) and tighten the mounting bolts (IN) torque of 8-10 Nm in several approaches.
18. Install intake manifold.
19. Install the exhaust manifold.
20. Connect the crankcase ventilation hose.
21. Connect the high voltage wires to the spark plugs.
22. Install the power steering pump bracket and tighten the mounting bolts (A) torque 35-50 Nm.
23. Install the power steering pump.
24. Install the throttle cable.
25. Connect the hose to the vacuum brake booster.
26. Connect the solenoid valve hose (A).
27. Connect the fuel hose (A).
28. Connect all connectors on the cylinder head and intake manifold.
29. Connect heater hoses (A).
30. Connect the top (A) and bottom (B) radiator hoses.
31. Install the air filter assembly with the intake hose.
32. Install the engine cover.
33. Connect the negative terminal to the battery.
34. Fill the coolant into the cooling system.
35. Start the engine and check all engine systems for leaks.
36. Recheck engine coolant and oil levels.