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 the gaskets on the cylinder block in accordance with the marking.
Note. The marks on the cylinder head gaskets correspond to: R7 - right, L7 - left.
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.
5. First tighten all cylinder head bolts to 25 Nm.
6. Retighten all mounting bolts by 60°.
7. Completely 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 rear drive belt cover (A). Tighten the mounting bolts to 10-12 Nm.
10. Install the chain on the camshafts so that the chain links marked with paint coincide with the alignment marks on the camshaft sprockets (as it shown on the picture).
11. Install camshafts (A) into the cylinder head.
12. Install the camshaft bearing caps (A). Tighten the bolts to 10-16 Nm.
Note. Before installing the covers, apply fresh engine oil to the bearing shells and camshaft bearing journals. Apply a thin layer of engine oil to the threads of the bolts.
13. Using a special tool (09214-21000), press in the camshaft seal.
14. Install the camshaft drive gears. Lightly bait, and then tighten the gear mounting bolts with a wrench to a torque of 90-110 Nm.
15. Install semicircular plugs.
16. 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.
17. Apply sealant to the corners of the cut.
Note. Use sealant No.5699. Ensure surfaces are dry and clean before applying sealant. After assembly, wait at least 30 minutes and only then pour engine oil into the engine.
18. Install cylinder head cover (A) and tighten the fastening bolts to a torque of 8-10 Nm in several approaches in the order shown in the figure.
19. Connect the high voltage wires to the spark plugs.
20. Install 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 vacuum 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 heater hoses.
31. Connect the top (A) and bottom (IN) radiator hoses.
32. Install air filter (WITH) complete with inlet hose. Connect breather hose (IN) and 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. Pour coolant into the cooling system.
37. Start the engine and check for leaks.
38. Recheck oil and coolant levels.