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 gaskets on the cylinder block in accordance with the markings.
Note: The marks on the cylinder head gaskets correspond to: R7 - right, L7 - left.
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.
5. First tighten all cylinder head mounting bolts to a torque of 25 Nm.
6. Tighten all mounting bolts again by 60°.
7. Finally tighten all mounting bolts by 45°.
8. Install the water pump assembly with the coolant temperature control unit (A). Tighten the mounting bolts to 15-20 Nm.
9. Install the rear drive belt cover (A). Tighten the mounting bolts to a torque of 10-12 Nm.
10. 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).
11. Install the camshafts (A) into the cylinder head.
12. Install the camshaft support bearing caps (A). Tighten the bolts to 10-16 Nm.
Note: Apply fresh engine oil to the bearing shells and camshaft journals before installing the caps. Apply a thin layer of engine oil to the threaded portion of the bolts.
13. Using a special device (09214-21000), press in the camshaft oil seal.
14. Install the camshaft drive gears. Lightly tighten and then tighten the gear mounting bolts with a wrench to a torque of 90-110 Nm.
15. Install the semicircular plugs.
16. 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.
17. Apply sealant to the corners of the recess.
Note: Use sealant 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.
18. Install the cylinder head cover (A) and tighten the mounting bolts to a torque of 8-10 Nm in several steps in the order shown in the figure.
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19. Connect the high-voltage wires to the spark plugs.
20. Install the drive belt.
21. Install the exhaust manifold.
22. Install the power steering pump.
23. Install the intake manifold.
24. Install the crankcase ventilation hose (A).
25. Install the throttle cable.
26. Connect the vacuum hose (A) to the brake booster.
27. Connect the crankcase ventilation hose.
28. Connect the fuel hose (A).
29. Connect the connectors in the reverse order of removal.
30. Connect the heater hoses.
31. Connect the upper (A) and lower (B) radiator hoses.
32. Install the air cleaner (C) complete with the intake hose. Connect the breather hose (B) and the mass air flow sensor connector (A).
33. Install the engine cover.
34. Connect the negative terminal to the battery.
35. Install the air intake (A).
36. Fill the cooling system with coolant.
37. Start the engine and check for leaks.
38. Recheck oil and coolant levels.