Note:
- Wash all parts before installation.
- Always use a new cylinder head gasket and exhaust and intake manifold gaskets.
- Always use new cylinder head bolts.
- Rotate the crankshaft clockwise to set the No. 1 cylinder piston to top dead center (TDC).
1. Clean the contact surfaces with the cylinder head gasket and the block, remove oil, dust and scratches.
2. Select cylinder head gasket:
Measure piston protrusion (at top dead center (TDC)) above the top surface of the cylinder block at eight points (A - H). Measurements should be taken above the center line of the crankshaft in the direction of piston movement.
Select a gasket from the table below using the average piston protrusion. Even if the piston protrusion value is outside the range corresponding to the average value at just one measurement point, a gasket one size thicker should be taken.
3. Install gasket (A) cylinder head to cylinder block.
4. Apply sealant to the upper surface of the cylinder block, then install the cylinder head gaskets and apply sealant to them:
Apply sealant (LOCTITE 5902 or equivalent) and assemble the cylinder head within 15 minutes.
Install the gasket firmly on the cylinder head.
Be careful not to damage the edges and coating of the cylinder head gasket before and after installing it.
5. Install the head (A) cylinder block, being careful not to damage the gasket.
6. Screw in bolts of fastening of a head of the block of cylinders:
Do not apply engine oil to the cylinder head bolts.
Using a special tool (09221-4А000), tighten the 10 cylinder head bolts in the sequence shown in the illustration several times.
Note:
- Tightening torque: 78.5 Nm + tighten 120°+ tighten 120°.
- Do not reuse cylinder head bolts.
Tighten side bolt (A) cylinder heads.
Note: Tightening torque: 30.4 - 34.3 Nm.
7. Install the hydraulic lifter (IN) and rocker (A):
The hydraulic compensator, until its installation, must be stored in a vertical position (to prevent engine oil leakage) and protected from dust.
Install the hydraulic compensator in the cylinder head carefully so as not to spill oil. In the event of an oil spill, bleed the air from the hydraulic lifter as described below:
Dip the hydraulic compensator into the oil 4-5 times, pressing down on its cap and at the same time lightly pressing the ball down with a stiff steel wire. (To avoid damaging the small ball, do not push the wire too hard.
8. Install the holder (A) camshaft with a new gasket.
Note: Before installing the camshaft holder, apply sealant (LOCTITE 518, THREEBOND 1389 or equivalent) on the rectangular area at the rear of the cylinder head.
9. Install the camshafts (A) and match the labels (B, C).
Attention. When installing camshafts, check the front and rear marks on the gears.
front
Behind
10. Install covers (A) camshaft bearings.
Note: Tightening torque: 10.8-12.7 Nm.
11. Remove the dowel pin (IN) (only motors of standard power.
Standard power
Reduced power
12. Install the vacuum pump (A) with new sealing ring (IN).
Attention. Take care not to lose the O-ring from the vacuum pump before installing the pump.
Note: Tightening torque: 7.8-11.8 Nm.
13. Install glow plugs (A) and connect the wiring harness (IN) with plates.
Note: Tightening torque:
- Glow plug: 15 - 20 Nm.
- Plate nut: 0.8 - 1.5 Nm.
14. Install the fuel rail (A).
Note: Tightening torque: 19.6 - 26.5 Nm.
15. Install the timing chain.
16. Install intake and exhaust manifolds.