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.
- The cylinder head gasket is metal, be careful not to bend it before installation.
- Rotate the crankshaft clockwise to set the number one piston to top dead center (TDC).
1. Install the oil control valve filter.
Attention. Keep the filter clean.
2. Install the cylinder head gasket (A) to the cylinder block.
Note:
- Pay attention to the installation order.
- Apply sealant (Loctite 5900H) to marked places (IN).
- After applying the sealant, the cylinder head must be installed within 5 minutes.
3. Install the cylinder head carefully so as not to damage the gasket.
4. Screw bolts of a head of the block of cylinders.
Apply a thin coat of engine oil to the threads and under the cylinder head bolt heads.
Using a hex wrench, tighten the 10 cylinder head bolts and washers in the order shown in the figure.
Note: Tightening torque: 32.4 -36.3 Nm + 90-95°+ 90-95°.
5. Install the valve (A) control of oil supply to intake valves.
Note: Tightening torque: 9.8 - 11.8 Nm.
6. Install valve (A) control of oil supply to the exhaust valves.
Note: Tightening torque: 9.8-11.8 Nm.
Attention.
- Do not damage or drop the oil control valves.
- Keep the filter clean.
- When oil control valves are installed on the engine, do not start the engine while holding the valve bracket.
7. Install camshafts.
Note: Apply a thin layer of engine oil to the camshaft bearings.
Install the lower exhaust camshaft bearing (A).
Install camshafts (A).
Install the upper bearing shell of the exhaust camshaft (A).
Reinstall the bearing caps in their original position.
Tightening order: group A -> group B -> group C. Tightening torque: step 1: M6: 5.9 Nm, M8: 14.7 Nm, step 2: M6: 10.8 - 12.7 Nm, M8: 27.5 - 31.4 Nm.
8. Install coolant outlet assembly (A).
Note:
Torque:
- Bolts: 14.7 - 19.6 Nm.
- Nuts: 18.6-23.5 Nm.
Attention.
- Install the coolant outlet assembly and water inlet hose to the water pump first, then tighten the inlet hose nuts.
- Always use new o-rings.
9. Screw in the bolt (A) water inlet fittings.
Note: Tightening torque: 9.8-11.8 Nm.
10. Install the timing chain.
11. Check valve clearance.
12. Establish a cover of a head of the block of cylinders.
Cured sealant located on the top surface between the chain cover and the cylinder head must be removed prior to installing the cylinder head cover.
After applying LOCTITE 5900H Sealant, assembly must be completed within 5 minutes.
Note: Sealant strip thickness: 2.5 mm.
It is forbidden to start the engine or carry out a pressure test for 30 minutes.
Install the cylinder head bolts as follows:
Tightening torque: step 1: 3.9-5.9 Nm, step 2: 7.8-9.8 Nm.
Attention. Do not reuse the cylinder head gasket.
13. Install intake and exhaust manifolds.
14. Connect hoses (A) cooling system to the throttle body.
15. Connect the fuel hose (A), vacuum hose (IN) brake booster and hoses (WITH) heater.
16. Connect wiring connectors and harness clamps.
(1) Oil Control Valve Connector (OCV) (A).
(2) Connector (A) intake manifold geometry change systems (VIS).
(3) Sensor connector (IN) oil pressure.
(4) Connector (WITH) knock sensor.
(5) Connector (D) air conditioner compressor switch.
(6) Generator connector (E).
(7) Connectors (A) nozzles.
(8) Connectors (IN) ignition coils.
(9) Connector (WITH) intake camshaft position sensor.
(10) Connector (D) exhaust camshaft position sensor.
(11) Connector (E) exhaust valve oil control valve.
(12) Connector (A) electronic throttle control systems (ETC).
(13) Connectors (IN) intake manifold absolute pressure sensor (IDA) and intake air temperature sensor (IATS).
(14) Connector (A) purge control solenoid valve (PCSV).
(15) Connector (IN) coolant temperature sensor (ECTS).
(16) Connector (WITH) capacitor.
(17) Connector (D) crankshaft position sensor.
(18) Connector (E) oxygen sensor.
17. Connect the top (A) and bottom (IN) radiator hoses.
18. Install engine protection (A).
Note: Tightening torque: 19.6-24.5 Nm.
19. Install the battery (D) and connect the positive terminal.
Note:
Torque:
- Positive terminal: 7.8-11.8 Nm.
- Bracket bolt: 9.8-11.8 Nm.
20. Install the air filter (WITH) assembly, then connect the air inlet hose (IN) and hose (A) breather.
Note:
Torque:
- Hose clamp bolt: 2.9-4.9 Nm.
- Air filter mounting bolts: 7.8-11.8 Nm.
21. Install the duct (WITH).
22. Install the cover (IN) engine.
23. Connect the negative wire (A) to the battery.
Note: Tightening torque: 4.0-6.0 Nm.
24. Do the following:
Fill with engine oil.
Before connecting the wires, clean their clamps and battery terminals with sandpaper. Coat attached clamps with grease to prevent corrosion.
Check for fuel leaks.
After installing the fuel line, turn the ignition key (do not turn on the starter), so that the fuel pump can operate for approximately 2 seconds and the fuel line is pressurized. Repeat this operation 2-3 times and check the entire fuel line for leaks.
Fill the radiator and reservoir with coolant.
Remove air from the cooling system.
Start the engine and let it warm up (until the radiator fan turns on 3-4 times).
Stop the engine and let it cool down. Check the coolant level and top up if necessary. This will remove air from the cooling system.
Replace the radiator cap tightly, restart the engine and check for leaks.