Removal and installation of a head of the block of cylinders: 1 - valve system with variable intake manifold geometry; 2 - gasket; 3 - intake manifold; 4 - right rear hook for lifting the engine; 5 - fuel manifold and injectors assy; 6 - node of the system with variable intake manifold geometry; 7 - insulator; 8 - cylinder head cover; 9 - camshaft bearing cap; 10 - camshaft 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 - ring seal; 24 - gasket; 25 - bracket No. 1 of the generator; 26 - bracket No. 2 of the generator; 27 - exhaust manifold bracket; 28 - inlet chamber; 29 - throttle body; 30 - bracket No. 1 of the inlet chamber; 31 - bracket No. 2 of the inlet chamber; 32 - gasket; 33 - cold start nozzle; 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 - 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 to the cylinder block, after installing a new cylinder head gasket.
Note: Incorrect gasket installation can cause severe engine damage.
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 any bolt is not tightened to the correct torque, 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°clockwise from its original position.
3. Install the camshafts.
- A) Place the camshaft in the cylinder head with the cam lobe #1. outward as shown in the figure.
- b) Apply sealant to bearing cap #1 as shown.
- V) Install bearing caps.
Note: each bearing cap has its own number and label "before".
- G) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.
- d) Install and evenly tighten the ten bearing cap bolts for each camshaft in several passes in the sequence shown.
- Tightening torque - 19 Nm
- e) Apply grease to the new oil seal.
- and) Using a mandrel (or pipe of suitable diameter), install the two camshaft seals.
4. Check up and if necessary adjust a backlash in a drive of valves.
Rotate the camshaft and place the cams with the cams up, check and adjust the clearance in the valve drive.
Valve clearance (cold engine):
- inlet - 0.15-0.25 mm
- graduation - 0.20-0.30 mm
5. Install the cylinder head cover.
- A) Apply sealant to the cylinder head as shown.
Note: If using an old gasket, lubricate the entire surface.
- b) Install two gaskets on the cylinder head cover.
- V) 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 pulleys.
9 Install the fuel manifold with 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 a new gasket and intake manifold. Tighten four bolts and three nuts in several passes.
- Tightening torque - 19 Nm
- b) Connect the knock sensor connector.
- V) Connect wire "grounding" and tighten the bolt
13. Install a new gasket and intake manifold variable geometry 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.
Torque:
- head 12 mm - 13 Nm
- head 14 mm - 19 Nm
15. Install the distributor.
16. Install the inlet chamber.
- A) Temporarily install the #1 intake plenum bracket by tightening the two bolts.
- b) Install a new gasket and intake plenum and temporarily tighten the six bolts and two nuts.
- V) Tighten the five bolts and two nuts securing the intake plenum and intake manifold evenly over several passes.
- Tightening torque - 19 N.m
- G) Tighten the three intake plenum bracket bolts Ns1.
- Torque:
- head 12 mm - 19 Nm
- head 14 mm - 39 Nm
- d) Install bracket #2.
- Tightening torque - 19 Nm
17. Install the cold start injector.
18. Establish knot of system of change of geometry of an inlet collector.
- A) Install the intake manifold changer assembly and tighten the three bolts.
- b) Connect the following hoses:
- (1) vacuum hose (from the electro-pneumatic valve of the fuel pressure regulator) from the intake manifold
- (2) vacuum hose (from electropneumatic valve) from the drive
- (3) vacuum hose (from the vacuum tank) from the intake manifold.
- V) Connect the following connectors:
- Electropneumocylvpan connector for fuel pressure regulator;
- Electropneumatic 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 the fuel pressure regulator,
- (2) two vacuum hoses for the power steering pump,
- (3) two vacuum hoses from the intake chamber,
- (4) vacuum hose from a vacuum tube (from the electro-pneumatic valve of the fuel pressure regulator).
21. Install the throttle body.
22 Install the coolant bypass pipe.
- A) Install a new O-ring on the tube.
- b) Apply soapy water to the O-ring.
- V) Install a new gasket to the water pump.
- G) Install the coolant bypass tube by tightening the two nuts and two bolts.
- Tightening torque - 8 Nm
- d) Connect the following hoses:
- (1) coolant bypass hose from the idle control valve,
- (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 switch.
24. Install the coolant outlet fitting.
- A) Install a new gasket and coolant outlet fitting 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 tube.
- (3) coolant bypass hose from the idle control valve.
- (4) Heater hose.
- V) Connect the following connectors:
- coolant temperature sensor connector,
- coolant temperature sensor,
- cold start injector timer connector.
25. Install the exhaust manifold.
- A) Install two new gaskets and exhaust manifold. Tighten the six nuts in several passes.
- Tightening torque - 43 Nm
- b) Install the right manifold bracket and right front engine lifting hook by tightening the three bolts and nut.
- Torque:
- bolts - 59 Nm
- nuts - 43 Nm
- V) Install the left manifold bracket, tighten the two bolts.
- Tightening torque - 59 Nm
- G) Connect and secure downpipe to 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 alternator by tightening the two bolts.
- b) Connect the generator connector.
- V) Connect the wire to the generator with a nut.
- G) Install alternator bracket #2.
- Tightening torque - 39 Nm
- d) Install the belt and adjust its tension, then tighten all bolts and nuts.
- Torque:
- head 12 mm - 19 Nm
- 14 mm head - 52 Nm
- e) Install the wire harness guard to the #2 timing belt cover bolts.
28. Fill in coolant.
29. Start the engine and check for leaks.
30. Adjust the ignition timing,
Ignition timing at idle - 8-12°to TDC (with closed outputs "TE1" And "E1").
31. Recheck the coolant and engine oil levels.