Attention.
- Always use a new cylinder head and manifold gasket.
- The cylinder head gasket is a metal gasket. Be careful not to bend it.
- Rotate the crankshaft to set the piston of the first cylinder to TDC.
- Do not use the middle cover and bottom cover to store removed parts.
- Clean the middle cover and bottom cover before installation.
1. Install the cylinder head gasket, dowel pins and oil adjustment hole into the cylinder head.
2. Tighten the cylinder head bolts in two stages. In the first stage, tighten all the bolts in the sequence shown in the figure to 29 Nm. In the final stage, tighten in the same sequence to 83 Nm.
Caution: Apply clean engine oil to the bolt threads and under the bolt head.
3. Install the intake manifold and tighten the nuts in a diagonal sequence in two or three steps, starting from the center.
- Always use a new intake manifold gasket.
4. Install the exhaust manifold and tighten the new self-locking nut in a diagonal sequence in two or three steps, starting from the center.
- Always use a new exhaust manifold gasket.
5. Install the camshaft and camshaft seals.
Attention.
- install the camshafts with the keyways facing up.
- the surface of the seal body must be dry.
- installed O-ring seal and locating pin in the lubrication channel of the camshaft holder No.3.
6. Apply the "liquid" gasket (P/N 0V740 - 99986 or 0BC70 - X0134S) to the main contact surfaces of holders No.1 and No.5 of both camshafts,
Caution: Clean and dry the cylinder head contact surfaces before applying the "liquid" gasket.
Apply "liquid" liner to shaded areas.
7. Install the camshaft holders and camshaft holder plate.
Note: The arrows marked on the camshaft holders must point towards the timing belt.
8. Tighten each bolt two turns at a time in the sequence shown in the illustration.
Caution: Remove excess "liquid" gasket from camshaft holders #1 and #5.
no.1 - No.10: 8x1.25 mm 27 Nm
Apply a coat of motor oil to the threads.
#11 - #14: 6x1.0 mm 9.8 Nm
9. Install the rear cover and camshaft pulleys,
10. Align the marks on the hole plug and the cylinder head, then install the plug into the cylinder head hole.
11. Install the timing belt.
12. Adjust the valve clearance.
13. Install the cylinder head cover gasket into the groove of the cylinder head cover.
Attention.
- Before installing the cylinder head cover gasket, completely clean the cylinder head cover gasket and groove.
- When installing, make sure the cylinder head cover gasket is placed securely without breaks.
14. Apply "liquid" gasket to the cylinder head cover gasket.
Attention.
- Use "liquid" gasket No.0Y740 - 99986 or 08C70-X0134S.
- Make sure the contact surfaces are clean and dry before applying the liquid gasket.
- Perform installation no later than 5 minutes after applying the "liquid" gasket.
- After assembly, wait at least 20 minutes before filling the engine with oil.
15. When installing the cylinder head cover, support the cylinder head cover gasket in the groove.
Once the cylinder head cover is seated on the cylinder head, move the cover back and forth slightly until it is fully seated.
Attention.
- Before installing the cylinder head cover, clean the contact surfaces of the cylinder head.
- Do not touch parts where the "liquid" gasket was applied.
16. Tighten the nuts in two or three stages. In the final stage, tighten all nuts in sequence to 9.8 Nm.
Caution: After assembly, wait at least 20 minutes before filling the engine with oil.
17. After installation, check that all tubes, hoses and connectors are installed correctly.