Removal and installation the cylinder head: 1 - valve of the variable geometry intake manifold system; 2 - gasket; 3 - intake manifold; 4 - right rear hook for lifting the engine; 5 - fuel manifold and injectors assembly; 6 - variable geometry intake manifold system unit; 7 - insulator; 8 - cylinder head cover; 9 - camshaft bearing cap; 10 - camshaft oil seal; 11 - cylinder head; 12 - intake manifold bracket; 13 - cylinder head gasket; 14 - air tube; 15 - gasket; 16 - heat-insulating sleeve; 17 - sealing washer; 18 - gasket; 19 - gasket; 20 - intake camshaft; 21 - exhaust camshaft; 22 - oil pressure sensor; 23 - O-ring seal; 24 - gasket; 25 - Generator bracket No.1; 26 - Generator bracket #2; 27 - exhaust manifold bracket; 28 - intake chamber; 29 - throttle body; 30 - Bracket No.1 of the intake chamber; 31 - Bracket No.2 of the intake chamber; 32 - gasket; 33 - cold start injector; 34 - gasket; 35 - pusher; 36 - adjusting washer; 37 - crackers; 38 - valve spring plate; 39 - valve spring; 40 - retaining ring; 41 - valve guide; 42 - valve; 43 - O-ring seal; 44 - left hook for lifting the engine; 45 - Coolant bypass pipe; 46 - gasket; 47 - Right front hook for lifting the engine; 48 - distributor; 49 - Coolant outlet pipe; 50 - gasket; 51 - Exhaust manifold heat shield; 52 - exhaust manifold; 53 - exhaust manifold bracket; 54 - spring seat.
Installing the cylinder head
1. Install the cylinder head onto the cylinder block, after installing a new cylinder head gasket.
Note: Incorrect installation of the gasket may cause serious engine damage.
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 torque - 49 Nm
- If the specified tightening 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 specified above.
- d) Check that the paint mark is offset clockwise by 90° from its original position.
3. Install the camshafts.
- a) Place the camshaft in the cylinder head with the working projection of cam No.1 facing outward, as shown in the figure.
- b) Apply sealant to bearing cap No.1 as shown in the figure.
- c) Install the bearing caps.
Note: Each bearing cap has its own number and "front" mark.
- d) Apply a thin coat of engine oil to the threads and under the heads of the bearing cap bolts.
- d) Install and tighten the ten bearing cap bolts for each camshaft evenly in several passes in the sequence shown in the illustration.
- Tightening torque - 19 Nm
- e) Apply grease to the new seal.
- g) Using a mandrel (or a pipe of suitable diameter), install two camshaft oil seals.
4. Check and, if necessary, adjust the valve clearance.
Turn the camshaft and position the cams with the working projections upward, check and adjust the clearance in the valve drive.
Valve clearance (cold engine):
- inlet - 0.15-0.25 mm
- outlets - 0.20-0.30 mm
5. Install the cylinder head cover.
- a) Apply sealant to the cylinder head as shown in the figure.
Note: When using an old gasket, lubricate the entire surface.
- b) Install two gaskets on the cylinder head cover.
- c) Install the cylinder head cover, ten washers and tighten the screws evenly in several passes.
- Tightening torque - 2.5 Nm
6. Install timing belt cover #3 by tightening the five bolts.
- Tightening torque - 9 Nm
7. Install the tension roller.
8 Install the camshaft timing pulleys.
9 Install the fuel manifold with the injectors installed (see by analogy with installation on engines 3S-FE, 4S-FE).
10. Install the engine wiring harness to the cylinder head cover.
- a) Install the engine wiring harness by tightening the two bolts
- b) Connect the injector connectors
11. Install the right rear engine lifting hook.
- Tightening torque - 19 Nm
12. Install the intake manifold.
- a) Install the new gasket and intake manifold. Tighten the four bolts and three nuts in several passes.
- Tightening torque - 19 Nm
- b) Connect the knock sensor connector.
- c) Connect the ground wire and tighten the bolt
13. Install the new gasket and VGA valve by tightening the two bolts and two nuts in several passes.
- Tightening torque - 19 Nm
14. Install the left engine lifting hook by tightening the two bolts.
Tightening torque:
- 12mm head - 13Nm
- 14mm head - 19Nm
15. Install the distributor.
16. Install the intake chamber.
- a) Temporarily install the intake plenum bracket No.1 by tightening the two bolts.
- b) Install the new gasket and intake chamber and temporarily tighten the six bolts and two nuts.
- c) Tighten the five bolts and two nuts securing the intake chamber and intake manifold evenly in several passes.
- Tightening torque: 19 Nm
- d) Tighten the three bolts of the Ns1 intake chamber bracket.
- Tightening torque:
- 12mm head - 19Nm
- 14mm head - 39Nm
- d) Install bracket No.2.
- Tightening torque - 19 Nm
17. Install the cold start nozzle.
18. Install the intake manifold geometry control system unit.
- a) Install the intake manifold variable geometry system unit and tighten the three bolts.
- b) Connect the following hoses:
- (1) vacuum hose (from the fuel pressure regulator solenoid valve) from the intake manifold,
- (2) vacuum hose (from the solenoid valve) from the drive,
- (3) Vacuum hose (from the vacuum tank) from the intake manifold.
- c) Connect the following connectors:
- Fuel pressure regulator electrical pneumatic valve connector;
- Electro-pneumatic valve connector.
19. Install the intake manifold bracket by tightening the two bolts.
- Tightening torque - 39 Nm
20. Install the air tube.
- a) Install the air tube by tightening the two bolts.
- b) Connect the following hoses:
- (1) vacuum hose from fuel pressure regulator,
- (2) two power steering pump vacuum hoses,
- (3) two vacuum hoses from the intake chamber,
- (4) vacuum hose from vacuum tube (from the fuel pressure regulator solenoid valve).
21. Install the throttle body.
22 Install the coolant bypass pipe.
- a) Install a new O-ring onto the tube.
- b) Apply soapy water to the O-ring.
- c) Install a new gasket on the coolant pump.
- d) Install the coolant bypass pipe by tightening the two nuts and two bolts.
- Tightening torque - 8 Nm
- d) Connect the following hoses:
- (1) Idle Air Control Valve Coolant Bypass Hose,
- (2) coolant bypass hose from the cylinder block,
- (3) two coolant bypass hoses from the oil cooler,
- (4) heater hose.
23. Apply sealant to two or three threads and install the oil pressure sensor.
24. Install the coolant outlet pipe.
- a) Install the new gasket and coolant outlet pipe by tightening the two bolts.
- Tightening torque - 39 Nm
- b) Connect the following hoses:
- (1) Upper radiator hose,
- (2) Coolant bypass hose from the bypass pipe.
- (3) Coolant bypass hose from idle air control valve.
- (4) Heater hose.
- c) Connect the following connectors:
- coolant temperature gauge sensor connector,
- coolant temperature sensor,
- cold start injector timer connector.
25. Install the exhaust manifold.
- a) Install two new gaskets and the exhaust manifold. Tighten the six nuts in several passes.
- Tightening torque - 43 Nm
- b) Install the right manifold bracket and the right front engine lift hook by tightening the three bolts and nut.
- Tightening torque:
- bolts - 59 Nm
- nuts - 43 Nm
- c) Install the left manifold bracket, tighten the two bolts.
- Tightening torque - 59 Nm
- d) Connect and secure the intake pipe to the exhaust manifold
- d) Install the heat shield by tightening the five bolts.
26. Install generator bracket #1 by tightening the three bolts.
- Tightening torque - 39 Nm
27. Install the generator.
- a) Install the generator by tightening two bolts.
- b) Connect the generator connector.
- c) Connect the wire to the generator using a nut.
- d) Install generator bracket No.2.
- Tightening torque - 39 Nm
- d) Install the belt and adjust its tension, then tighten all bolts and nuts.
- Tightening torque:
- 12mm head - 19 Nm
- 14mm head - 52Nm
- e) Install the wiring harness protector onto the timing belt cover bolts No.2.
28. Fill with coolant.
29. Start the engine and check for leaks.
30. Adjust the ignition timing,
The ignition advance angle at idle speed is 8-12° before TDC (with terminals "TE1" and "E1" closed).
31. Recheck the coolant and engine oil levels.