Cylinder head — installation

Installing the cylinder head

1. Install the cylinder head on the cylinder block by installing a new cylinder head gasket on the block

2. Establish bolts of fastening of a head of the block of cylinders.

Note:

• The cylinder head bolts are tightened in the dev stage.
• If any cylinder head bolt is broken or deformed, replace it.

• A) Apply a light coat of engine oil to the threads and under the heads of the mounting bolts.
• b) Install and using an 8 mm wrench progressively tighten in several passes (at least 3) block head bolts in the sequence shown in the figure.
• Tightening torque - 44 Nm

Note: bolts (A), marked in the figure are longer than the bolts (IN).

If any bolt is not tightened to the correct torque, replace the bolt.

• G) Apply paint marks to the front of the cylinder head bolts.

• d) Tighten the cylinder head bolts 90°.
• e) Check that the inked mark is 90°from its original position.

3. Assemble the intake camshaft.

• A) Clamp the hex section of the camshaft in a vise.

Note: Do not damage the camshaft.

• b) Install the following parts:
  • leaf spring (3) camshaft gears;
  • auxiliary gear (2) camshaft drive;
  • spring washer (1).

Note: Align the pins on the gears with the ends of the leaf spring (3), as it shown on the picture.

• V) Using pliers, install the retaining ring.

• G) Insert process bolt (A) in the technological hole of the auxiliary gear of the camshaft drive.
• d) Using a screwdriver, align the hole of the camshaft drive main gear and the sub gear by turning the camshaft drive sub gear clockwise; then install the technological bolt (IN).

4. Install the camshafts

Note: when installing camshafts, it must be taken into account that the axial clearance is very small; therefore, the shafts must be laid in the bed of bearings strictly horizontally, without distortions, in order to avoid jamming and / or damage to the shafts.

To avoid this, follow the following sequence of procedures.

• A) Apply a layer of engine oil to the end thrust surfaces of the camshaft.
• b) Install the intake camshaft as shown, with the intake camshaft service bolt up and the #3 and #4 cam lugs down.
• V) Install the four bearing caps in their respective locations.

• G) Temporarily tighten the bearing cap bolts by alternately tightening the right and left bolts in the sequence shown in the figure.

• d) Apply engine oil to the ends of the exhaust camshaft.
• e) Engage the exhaust and intake camshaft drive gears by aligning the alignment marks on these gears with each other.

• and) Keeping the gears engaged, roll the exhaust camshaft into its journals on the cylinder head.

• h) Push lightly on the exhaust camshaft towards the front of the engine, but do not apply much force.
• And) Install the four exhaust camshaft bearing caps.

• To) Temporarily tighten the bearing cap bolts evenly and alternately.

• l) Turn away a technological bolt.

• m) Clean the surface of the N22 bearing cap and apply sealant to the area indicated in the figure.

• n) Install the Ne2 bearing cap, and then check that there is no clearance between the cylinder head and the contact surface of the bearing cap.
• O) Tighten the #2 bearing cap bolts evenly and alternately for a while.

• P) Install the intake camshaft cap.
• R) Install and tighten the ten intake camshaft bearing cap bolts alternately and evenly in the sequence shown in the figure.
• Tightening torque - 13 Nm

• With) Apply sealant to the new camshaft seal and install the new seal as deep as possible into the cylinder head.

• T) Clean the surface of the #1 bearing cap and apply sealant to the area indicated in the illustration.

• at) Install bearing cap No. 1, then check for clearance between the cylinder head and the contact surface of the bearing cap
• f) Tighten the #1 bearing cap bolts evenly and alternately for a while

• X) Install and tighten the ten exhaust camshaft bearing cap bolts alternately and evenly in the sequence shown in the figure.

• Tightening torque - 13 Nm
• c) Turn the camshafts and check the alignment of the alignment marks.

5. Install the camshaft sprocket.

• A) Align the exhaust camshaft locating pin with the pin groove on the sprocket and install the sprocket.
• b) Holding the camshaft with a wrench at the hex section. tighten the toothed pulley bolt.
• Tightening torque - 50 Nm

6. Install the intermediate pulley and tighten the bolt.

• Tightening torque - 27 Nm

7. Install the timing belt.

• A) Rotate the crankshaft pulley and align the notch on the pulley with the alignment mark (ledge) on cover #1 of the timing belt.

Note: Check that the timing belt is correctly installed on the crankshaft sprocket and on the oil pump pulley.

• b) Rotate the camshaft and align the alignment hole on the camshaft sprocket with the alignment mark on the Nel bearing cap.
• V) Place the timing belt on the camshaft sprocket as shown in the illustration and turn the camshaft to install the belt.

• G) Loosen the idler pulley mounting bolt until it moves slightly under the action of the spring.
• d) Rotate the crankshaft pulley two turns (from TDC to TDC).

Note: Turn the crankshaft only clockwise.

• e) Check that all alignment marks on all pulleys are aligned.

If the alignment marks are not aligned, then remove the timing belt and reinstall it.

8. Install timing belt cover #3.

9. Install the alternator drive belt. Temporarily tighten the axle bolt nut and adjust the belt tension.



10. Install timing belt cover #2 by installing gasket and tighten with four bolts.

11. Install the cylinder head cover

• A) Apply sealant to the cylinder head as shown.

• b) Install the gasket on the cylinder head cover.
• V) Install the cylinder head cover and tighten the five sealing washers.
• Tightening torque - 7 Nm

12. Install the intake manifold.

• A) Install new gasket and intake manifold, tighten three nuts and three bolts
• Tightening torque - 19 Nm

• 6) Install the manifold bracket by tightening the two bolts and nuts.
• Tightening torque - 19 Nm

13. Install the air tube by tightening the two bolts.



14. Install the injectors and fuel manifold.

15. Install the throttle body.

16. Install the air bypass valve to the outlet.

• A) Install the O-ring from the air bypass valve.
• b) Apply soapy water to the O-ring.
• V) Connect two bolts, wire "grounding" and an air bypass valve to the outlet.
• G) Connect the valve connector.

17. Install the exhaust manifold.

• A) Install a new gasket and tighten the six nuts.
• Tightening torque - 47 Nm

• b) Install the heat shield and tighten the three bolts.
• Tightening torque - 8 Nm

18. Install thermostat and outlet tubes

• A) Remove the old sealing material and clean the surface as shown in the figure.

Note: Use a scraper or scraper to remove and clean surfaces with a non-residue solvent.

• b) Apply sealant as shown.

• e) Install the thermostat and tighten the two bolts.
• Tightening torque - 19 Nm

• G) Connect the following hoses:
  • Coolant Inlet Hose (1).
  • Heater outlet hose (2).
  • coolant bypass hose (3)
  • Two vacuum hoses of a thermally controlled pneumatic valve (4).

• d) Connect the following connectors:
  • Sensor connector - switch for coolant temperature (to the electric fan drive of the cooling system) (1).
  • Connector coolant temperature sensor (2).
  • Coolant temperature gauge sensor connector (3).
  • (Models with automatic transmission) Coolant Temperature Switch Sensor Connector (4).

18. Install the EGR pipe, vacuum modulator and EGR valve.

• A) Install the gasket and EGR valve, tighten the two nuts.
• Tightening torque - 17 Nm
• b) Install the vacuum modulator.

• V) Install a new gasket and EGR pipe by tightening the two fastening nuts. Tighten the union nut of the tube.
• Torque:
  • union nut - 39 Nm
  • fastening nuts - 29 Nm

19. Connect the vacuum hoses, power steering pump.

• A) (Models with automatic transmission) Connect the following hoses:
  • Vacuum hose from throttle actuator (1).
  • Vacuum hose from EGR valve (2).
  • Three vacuum hoses from the EGR vacuum modulator (3).

• b) Connect the vacuum hose from the fuel vapor accumulator.

20. Install spark plugs.

• Tightening torque - 19 Nm

21. Connect the high voltage wires by tightening the bolt securing the high voltage wire holders to the cylinder head cover.