A. Check protrusion of No. 1 and No. 4 pistons.
A) Align the TDC mark on the crankshaft pulley with the benchmark.
b) Install a dial indicator on the cylinder block, place the indicator tip on the piston crown.
V) Slowly turning the crankshaft clockwise and counterclockwise, find the point where the piston crown protrudes the maximum distance.
G) Set the zero readings of the dial indicator to 0 mm.
d) Measure the protrusion of the piston from the cylinder block by moving the dial indicator.
- Protrusion - 0.68 - 0.97 mm
Note: Check protrusion on at least two points.
If the protrusion is not as specified, remove the connecting rod and piston group and replace it.
B. Check protrusion of No. 2 and No. 3 pistons.
A) Rotate the crankshaft half a turn (180°).
b) Measure piston protrusion as described above.
B. Select a new cylinder head gasket.
Note: There are three sizes of new cylinder head gaskets which are marked with either letters "IN", "D" or "F", or the location of the cutout.
New cylinder head gasket thickness:
- Marking B - 1.40 - 1.50 mm
- Marking D - 1.50 -1.60 mm
- Marking F - 1.60- 1.70 mm
When choosing a new head gasket, use the largest protrusion.
Recommendation: Factory installed 6 types of head gaskets (marked from A to F), but only three types are available as spare parts (B, D and F), therefore, when replacing the gasket, you must choose from the three types indicated above.
2. Set the piston position in cylinder No. 1 to TDC.
A) Install the camshaft with the keyway up.
b) Align the TDC mark on the crankshaft pulley with the benchmark.
3. Install the cylinder head.
A. Place the head on the cylinder block.
A) Put a new one on the cylinder block.
Note: Orient the gasket correctly.
b) Install the cylinder head on the pins.
B. Install the block head bolts.
Note: The cylinder head bolts are tightened in three consecutive steps.
If any of the bolts are broken or deformed, replace them.
A) Apply a light coat of engine oil to the threads and headrests of the cylinder head bolts.
b) First, install and evenly tighten the eighteen cylinder head bolts in several passes in the sequence shown in the figure.
- Tightening torque - 78 Nm
Note: Types A and B bolts shown in the figure have lengths: Type A - 107 mm; type B - 127 mm.
If any of the bolts does not meet the tightening torque requirements, replace it.
V) Mark the cylinder head bolts.
G) On the second pass, turn the cylinder head bolts 90°in the same sequence as above.
d) On the third pass, turn the cylinder head bolts an additional 90°.
e) The label should now be facing the back.
4. Install the valve cover.
A) Position the packing material in the cylinder head as shown in the illustration.
b) Place the gasket on the cylinder head cover.
V) Reinstall the head cover with eight bolts and two nuts.
- Tightening torque - 4.9 Nm
5. Install the right engine hanger.
- Tightening torque - 37 Nm
6. Install the exhaust manifold.
A) Install a new gasket and exhaust manifold.
- Tightening torque - 52 Nm
b) Install the heat shield with four bolts.
7. Install intake manifold.
A) Place a new gasket on the cylinder head with the tab facing up.
b) Install a new gasket and intake manifold.
V) Tighten the intake manifold nuts and bolts.
- Tightening torque - 24 Nm
8. Install the left engine hanger.
- Tightening torque - 37 Nm
9. Install the water tube and water tube housing.
A) Install a new gasket, water tube and water tube housing.
- Tightening torque - 19 Nm
b) (With heating control). Connect the bypass hose to the temperature control unit.
10. Install the top timing belt cover with four bolts.
- Tightening torque - 18 Nm
11. Install the camshaft pulley.
12. Install nozzles.
13. Install the timing belt (see related section).
14. Fill the engine with coolant (see related section).
15. Start the engine and check for leaks.
16. Check coolant and oil levels.