2. Install the cylinder head mounting bolts.
Note:
- The cylinder head mounting bolts are tightened in two stages.
- If any cylinder head mounting bolt is broken or deformed, replace it.
a) Apply a thin layer of engine oil to the threads and under the heads of the mounting bolts.
b) Install and tighten the 10 cylinder head bolts and plate washers evenly in several passes, in the sequence shown in the figure.
- Tightening torquei — 49 Nm
If the specified torque is not achieved when tightening any bolt, replace the bolt.
c) Apply paint marks to the front of the cylinder head bolts.
d) Tighten the cylinder head bolts by 90, in the sequence shown above.
d) Check that the painted mark is 90 degrees from its original position.
2. Install the spark plug tubes (if you filmed).
a) Clean the spark plug tube holes in the cylinder head. Remove oil with kerosene or gasoline.
b) Apply sealant to the threads of the spark plug tubes and install the tubes into the cylinder head.
c) Using the spark plug tube nut and a 30mm socket wrench, tighten the spark plug clamp tubes.
- Tightening torque - 39 Nm
3. Assemble the exhaust camshaft (if you took it apart).
a) Place the camshaft in a vice.
Note: Be careful not to damage the camshaft.
b) Install the following parts:
- (1) Camshaft gear spring ring.
- (2) Auxiliary gear of the camshaft drive.
- (3) Spring washer.
Note: Align the guide pins on the gears with the ends of the spring.
c) Using the tool, install the retaining rings.
d) Insert the technological bolt "A" into 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 auxiliary gear by turning the auxiliary camshaft drive gear clockwise; then install the technological bolt (B).
Note: Do not damage the camshaft.
e) Align the teeth of the main and auxiliary gears and tighten the technological bolt B.
4. Install the camshafts. Note: When installing the camshafts, it is necessary to take into account that the axial clearance value is very small; therefore, the shafts must be placed in the bearing beds strictly horizontally, without distortion, to avoid jamming and/or damage to the shafts.
A. Install the intake camshaft.
a) Apply a layer of engine oil to the end bearing surfaces of the camshaft.
b) Set the intake camshaft to 80-115° until the piston of the first cylinder is at TDC.
Note: At these angles, the cam lobe projections of cylinders No.1 and No.3 of the intake camshaft press on the tappets.
c) Apply sealant to bearing cap #1 as shown.
d) Install the bearing caps in accordance with the markings on their housings.
d) Apply a thin coat of engine oil to the threads and under the heads of the bearing cap bolts.
e) Install and tighten the 10 bearing cap bolts evenly in several passes, in the sequence shown in the figure.
- Tightening torque - 19 Nm
g) Apply grease to the new seal.
c) Using a drift of suitable diameter and a hammer, install the seal.
B. Install the exhaust camshaft.
a) Set the inlet camshaft alignment pin to the 10 - 45° BTDC position.
Note: At these angles, the projections of cams No.2 and No.4 of the intake camshaft cylinders press on the tappets.
b) Apply a layer of engine oil to the end bearing surfaces of the camshaft.
c) Engage the gears of the exhaust and intake camshaft drives, aligning the timing marks on the gears with each other.
d) Keeping the gears engaged, roll the exhaust camshaft into the seats of its journals on the cylinder head.
Note: If there are also assembly marks on the gears as shown in the figure, do not use these marks for installation.
d) Turn the intake camshaft clockwise until the exhaust camshaft fits into the bearing journals without rolling.
Note: It is very important to follow the tightening sequence of the bearing cap bolts in the following steps.
e) Install the bearing caps.
g) Apply a thin coat of engine oil to the threads and under the heads of the bearing cap bolts.
c) Install and tighten the 10 bearing cap bolts evenly in several passes, in the sequence shown in the figure.
- Tightening torque - 19 Nm
i) unscrew the technological bolt "B".
k) Turn the camshafts and check the alignment of the marks on the gears.
5. Turn the camshaft and position the cams with the working projections facing up, check and adjust, if necessary, the clearance in the valve drive.
Valve clearance (cold engine):
- inlet - 0.19-0.29 mm
- outlet 0.28-0.38 mm
6. Install segment plugs (if they were filmed).
a) Remove the old sealing material.
b) Apply sealant to the segment plugs as shown in the figure.
c) Install two segment plugs into the cylinder head.
7. Install the high-voltage wire clamps, PCV valve and cylinder head cover hose.
a) Install the high-voltage wire clamps (1) by tightening the bolt.
b) Install the crankcase ventilation valve (2), having previously lubricated it with sealant before installation, the hose (3) and the seal (4).
c) Install the crankcase ventilation hose (3).
8. Install the cylinder head cover.
a) Remove any remaining old gasket.
b) Apply sealant to the cylinder head as shown in the figure.
Note: When using an old gasket, lubricate the entire surface.
c) Install the gasket on the cylinder head cover.
d) Install the cylinder head cover and spark plug tube seals with nuts. Tighten the nuts evenly in several passes.
- Tightening torque - 23 Nm
Note: Install the spark plug tube seals so that their marks are positioned as shown in the illustration.
9. Install the oil pressure sensor, having previously applied a special fixing adhesive (or sealant) on 2 or 3 thread turns of the sensor.
10. Install the generator bracket and right engine lifting hook by tightening the three bolts.
- Tightening torque - 42 Nm
11. Install the rear timing belt cover by tightening the four bolts.
- Tightening torque - 8 Nm
12. Temporarily install the tension roller and spring.
a) Align the bracket guide pin hole with the pin.
b) Install the tension roller and bolt; do not tighten the bolt.
c) Install the tensioner spring.
d) Press the roller to the left as far as possible and tighten the bolt.
d) Check that the tension roller moves freely.
13. Install the camshaft timing pulley.
a) Align the camshaft dowel pin with the dowel groove and install the camshaft timing pulley onto the shaft.
b) Tighten the pulley mounting bolt.
- Tightening torque - 54 Nm
14. Install the timing belt onto the camshaft sprocket.
a) Turn the crankshaft until its timing marks are aligned.
b) Install and check the alignment of the crankshaft and camshaft pulley marks.
15. Install the injectors into the fuel manifold.
a) Install new sealing bushings on each injector.
b) Apply a thin layer of fuel to the O-rings.
c) Rotate the injectors, press them towards the fuel manifold and install the injectors.
d) Install the injector connector upwards.
d) Install four new insulators and two spacers.
Note: It is better to glue the bushings.
e) Install the fuel manifold together with the injectors onto the cylinder head.
g) Temporarily tighten the two bolts securing the fuel manifold to the cylinder head.
c) Check the smooth rotation of the injectors.
Note: If the injectors do not rotate evenly, the likely cause is improper installation of the O-rings. Replace the O-ring.
i) Install the injector connectors upward.
k) Tighten the two bolts securing the fuel manifold to the cylinder head.
- Tightening torque - 13 Nm
l) Connect the injector connectors.
16. Install the intake manifold.
a) Install the new gasket and intake manifold, tightening the six bolts and two nuts in several passes
- Tightening torque - 19 Nm
b) Install the two engine wire clamps to the wire brackets on the intake manifold.
c) Install the two engine wiring harness protection clamps to the upper timing belt cover mounting bolts in the sequence shown in the figure.
d) Connect the following hoses:
- (1) Crankcase ventilation hose to intake manifold.
- (2) Vacuum hose from the air conditioner idle speed increase valve to the intake manifold.
- (3) Manifold Absolute Pressure Sensor Vacuum Hose to Gas Filter.
- (4) Brake booster vacuum hose to intake manifold.
17. (Models with EGR system) Install the EGR valve by tightening the bolt.
18. Connect the fuel return hose to the tube.
19. Connect the fuel supply hose to the fuel manifold.
a) Temporarily connect the fuel supply hose with two new gaskets and the fuel pressure pulsation damper.
b) Install a fuel pressure pulsation damper.
- Tightening torque - 34 Nm
c) Install the engine wiring harness clamp and the wiring harness clamp.
20. Install the vacuum tube.
a) Install the vacuum tube by tightening the two bolts.
b) Connect the following hoses:
- (1) Vacuum hose (from the gas filter) to the fuel pressure regulator.
- (2) Vacuum hose (from the fuel pressure regulator) to the gas filter.
- (3) Power steering pump air bypass control valve vacuum hose to intake manifold.
- (4) Vacuum hose of the idle speed increase valve when the air conditioner is turned on.
(5) Two vacuum hoses of the power steering pump air bypass control valve.
21. Connect:
- (1) Knock sensor connector,
- (2) (Models with EGR system) exhaust gas recirculation system electropneumatic valve connector,
- (3) ground wire.
22. Install intake manifold bracket #1 by tightening the two bolts.
- Tightening torque - 42 Nm
23. (Models with EGR system) Install the EGR valve and vacuum modulator.
a) Install the new gasket and EGR valve by tightening the union nut and two mounting nuts.
Tightening torque:
- fastening nuts - 13 Nm
- union nut - 59 Nm
b) Connect the following hoses:
- (1) Vacuum hose (from the exhaust gas recirculation valve) to channel "E" of the EGR system solenoid valve.
- (2) Vacuum hose (from channel "Q" of the EGR pressure modulator) to channel "G" of the EGR solenoid valve.
24. Install intake manifold bracket No.2 and left engine lifting hook by tightening the bolt and nut.
- Tightening torque - 42 Nm
25. Install the throttle body.
a) Install the new gasket onto the intake manifold, with the tab facing down.
b) Install the throttle body by tightening four bolts or two bolts and two nuts.
- Tightening torque - 19 Nm
Note: Different bolt lengths are used: top and bottom.
Bolt length:
- top - 40 mm
- lower - 55 mm
c) Connect the following hoses:
- (1) Crankcase ventilation hose to throttle body.
- (2) (Models with exhaust gas recirculation system) Two vacuum hoses (from the EGR pressure modulator) to the throttle body.
- (3) (Models with fuel vapor recovery system) Vacuum hose (from a temperature-controlled pneumatic valve of the fuel vapor recovery system) to the throttle body.
- (4) Vacuum hose (from idle speed control valve) to the tube.
d) Connect the following connectors:
- (1) Throttle position sensor connector,
- (2) Idle speed control valve connector.
26. Install the coolant bypass pipe.
a) Install a new gasket to the coolant pump cover.
b) Install a new O-ring on the coolant bypass pipe.
c) Apply soapy water to the O-ring.
d) Connect the coolant bypass pipe to the coolant pump cover.
d) Install the cooling system bypass pipe by tightening the two nuts and two bolts.
Tightening torque:
- nuts - 9 Nm
- bolts - 19 Nm
e) Connect the following hoses:
- (1) Idle Air Control Valve Coolant Bypass Hose to Coolant Bypass Tube.
- (2) Heater hose to coolant bypass pipe.
- (3) (Models with oil radiator) Two oil cooler coolant bypass hoses.
27. Install the coolant outlet pipe.
a) Install a new gasket and the coolant outlet pipe by tightening the two nuts.
- Tightening torque - 15 Nm
b) Connect the following hoses:
- (1) Upper radiator hose,
- (2) Coolant bypass hose,
- (3) Heater hose,
- (4) Idle Air Control Valve Coolant Bypass Hose,
- (5) (Models with fuel vapor recovery system) vacuum hose of the temperature-controlled pneumatic valve (from channel "P" of the throttle body),
- (6) (Models with fuel vapor recovery system) vacuum hose of thermo-controlled pneumatic valve (from fuel vapor accumulator).
c) Connect the following connectors:
- (1) Coolant temperature gauge sensor connector;
- (2) Coolant temperature sensor connector;
- (3) Oil pressure sensor connector.
29. Install the exhaust manifold.
a) Install the lower heat shield to the exhaust manifold by tightening the three bolts.
b) Install the new gasket and exhaust manifold, tightening the six nuts evenly and in several passes.
- Tightening torque - 49 Nm
c) Install the manifold bracket by tightening the bolt and nut and install the exhaust pipe.
- Tightening torque - 42 Nm
d) Install the upper heat shield by tightening the five bolts.
30. Install the distributor.
a) Turn the crankshaft clockwise and set the inlet camshaft cut as shown in the figure.
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b) Check the condition of the O-rings and replace them if necessary.
c) Apply a thin coat of engine oil to the O-ring.
d) Align the cut of the coupling with the protrusion on the body
d) Insert the distributor, align the center of the flange with the bolt hole on the cylinder head.
Note: The cut is off-center and therefore the distributor can only be inserted one way.
e) Lightly tighten the two bolts.
g) Connect the high-voltage wires to the spark plugs.
c) Connect the two distributor connectors.
31. Install the generator.
a) Install the generator hinge, lock bolt (models with air conditioning) or adjusting bolt (models without air conditioning). Do not tighten the bolts.
b) Install the alternator drive belt.
c) Adjust the belt tension.
d) Tighten the hinge bolt, lock bolt (models with air conditioning) and the adjusting bolt (models without air conditioning)
Tightening torque:
- hinge bolt - 54 Nm
- lock bolt or adjusting bolt - 19 Nm
d) Connect the generator connector.
e) Connect the generator wire, tighten the nut and install the rubber cap.
g) Install the wiring clamp to the clamp on the generator.
32. Install the throttle cable bracket by tightening the two bolts,
33. Fill the radiator with coolant.
34. Connect the control cables.
35. Connect the negative battery terminal.