Note.
- 1. Clean all surfaces thoroughly before installation.
- 2. Always use new gaskets.
- 3. The cylinder head gasket is metal. 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 the gasket (A) on the cylinder block.
2. Install the cylinder head carefully so as not to damage the gasket.
3. Insert washers and apply engine oil to the cylinder head mounting bolts.
4. Tighten and then tighten the cylinder head bolts in the order shown in the figure in several stages.
Tightening torques for 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 filter gasket and clean the filter each time it is removed.
6. Install the phase shifter dispenser (A). Phase shifter tightening torque: 10-12 Nm.
7. Install the chain on the camshafts so that the painted chain links coincide with the timing marks on the camshaft sprockets (as shown in the figure).
8. Install the camshafts (A) into the cylinder head. Install the camshaft main bearing caps (B) and tighten the mounting bolts to 14-15 Nm.
9. Install the camshaft chain tensioner (A). Remove the retainer (B).
10. Check and adjust valve clearance.
11. Using a special device (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 the gasket (A) into the recess in the cylinder head (B).
Note:
- Before installation, thoroughly clean the gasket and cylinder head recess.
- During installation, ensure that the gasket is installed without protruding parts.
16. Apply sealant to the corners of the recess.
Note: Use sealants No.5699. Before applying the sealant, make sure 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 the cylinder head cover (A) and tighten the mounting bolts (B) to a torque of 8-10 Nm in several passes.
18. Install the 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) to 35-50 Nm.
23. Install the power steering pump.
24. Install the throttle cable.
25. Connect the hose to the 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 the heater hoses (A).
30. Connect the upper (A) and lower (B) radiator hoses.
31. Install the air filter assembly with the inlet hose.
32. Install the engine cover.
33. Connect the negative terminal to the battery.
34. Fill the cooling system with coolant.
35. Start the engine and check all engine systems for leaks.
36. Recheck the engine coolant and oil levels.