2. Establish bolts of fastening of a head of the block of cylinders.
Note:
- - The cylinder head bolts are tightened in two stages.
- - 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 evenly tighten the 10 cylinder head bolts and plate washers in several passes in the sequence shown.
- Tightening torque - 49 Nm
If, when tightening any bolt. the required tightening torque is not reached, replace the bolt.
V) Apply paint marks to the front of the cylinder head bolts.
G) Tighten the cylinder head bolts 90°in the above sequence.
d) Check that the inked mark is 90°from its original position.
2. Install spark plug tubes (if 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 to the cylinder head.
V) Using the spark plug tube nut and 30mm socket wrench, tighten the spark plug tubes.
- Tightening torque - 39 Nm
3. Assemble the exhaust camshaft (if dismantled).
A) Install the camshaft in a vise.
Note: be careful not to damage the camshaft.
b) Install the following parts:
- (1) Camshaft gear snap ring.
- (2) Auxiliary camshaft drive gear.
- (3) Spring washer.
Note: Align the drive pins on the gears with the ends of the spring.
V) Using a tool, install the circlips.
G) Insert process 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 sub gear by turning the camshaft drive sub gear clockwise; then install the technological bolt (IN).
Note: Do not damage the camshaft.
e) Align the teeth of the main and auxiliary gears, and tighten the service bolt B.
4. Install camshafts.
Note: when installing camshafts, it must be taken into account that the axial clearance is very small, so the shafts must be laid in the bearing bed strictly horizontally, without distortion, in order to avoid jamming and / or damage to the shafts.
A. Install the intake camshaft.
A) Apply a layer of engine oil to the end thrust surfaces of the camshaft.
b) Set the intake camshaft to 80-115°until the No. 1 cylinder is at TDC.
Note: At these angles, the lobes on the No. 1 and No. 3 cylinders of the intake camshaft press on the tappets.
V) Apply sealant to bearing cap #1 as shown.
G) Install the bearing caps in accordance with the markings on their housings.
d) Apply a light coat of engine oil to the threads and subheads of the bearing cap bolts.
e) Install the #3 bearing cap and tighten the cap bolts evenly in several passes.
- Tightening torque - 19 Nm
and) Install and evenly tighten the bearing cap bolts in several passes, in the following sequence: No. 4 - No. 2 - No. 5.
- Tightening torque - 19 Nm
h) Apply grease to the new oil seal.
And) Using a drift of the correct diameter and a hammer, install the oil seal
B. Install the exhaust camshaft.
A) Set the inlet camshaft locating pin to 10-45 BTDC.
Note: at the same time, the protrusions of the cams No. 2 and No. 4 of the intake camshaft cylinders press on the pushers.
b) Apply a coat of engine oil. on the end thrust surfaces of the camshaft.
V) Engage the exhaust and intake camshaft drive gears by aligning the alignment marks on the gears with each other.
G) Keeping the gears engaged, roll the exhaust camshaft into its journals on the cylinder head.
Note: If there are also match marks on the gears, as shown in the picture, then do not use these marks for installation.
d) Rotate the intake camshaft clockwise until the exhaust camshaft is seated in 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 bearing caps.
and) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.
h) Install the #3 bearing cap and tighten the cap bolts evenly in several passes.
- Tightening torque - 19 Nm
And) Install and evenly tighten the bearing cap bolts in several passes in the following sequence: #2 - #4 - #1 - #5.
To) Loosen the technological bolt "IN".
l) Turn the camshafts and check the alignment of the marks on the gears.
5. Turn the camshaft and place the cams with the working projections up, check and adjust, if necessary, the clearance in the valve drive.
6. Install segment plugs (if filmed).
A) Remove old sealing material.
b) Apply sealant to the segment plugs as shown.
V) install two segment plugs in the cylinder head.
7. Install the cylinder head cover.
A) Remove the remnants of the old gasket.
b) Apply sealant to the cylinder head as shown.
Note: If using an old gasket, lubricate the entire surface.
V) Install the gasket on the cylinder head cover.
G) 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 located as shown in the illustration.
Connect a reception pipe of system of release.
Torque:
- fastening to the exhaust manifold - 63 Nm
- fastening to the intermediate pipe of the exhaust system - 44 Nm
9. Install vacuum reservoir stand #2.
- Tightening torque - 44 Nm
10. Connect the coolant bypass pipe.
- Tightening torque - 20 Nm
11. Connect the heater outlet hose.
12. Connect the coolant bypass hose.
13. Connect the fuel inlet hose and fuel return hose.
14. Connect the radiator inlet hose.
15. Establish the generator in gathering and an adjusting lath of the generator.
Torque:
- fastening to the bracket - 53 Nm
- mounting to the coolant pump - 22 Nm
16. Connect the wiring harness.
17. Connect vacuum hoses.
18. Install the accelerator cable bracket.
19. Connect throttle control cable (automatic transmission).
20. Connect the accelerator cable.
21. Install the distributor (4S-FE) or combined ignition unit (3S-FE).
22. Install the timing belt (see section "timing belt").
23. Fill in cooling liquid from the engine.
24. Disconnect the negative plug from the storage battery.