Attention:
- Always use a new cylinder head gasket.
- The cylinder head and cylinder block surface MUST be CLEAN.
- Label "UP" on the camshaft pulley should be at the top.
- Turn the crankshaft until the piston of the first cylinder is installed at TDC.
- Clean the oil control hole before installation.
- Do not use the top and bottom covers to store removed parts.
- Clean the top and bottom covers before installation.
1. Align the cylinder head locating pins.
2. Position the camshaft correctly (see above).
3. Tighten the cylinder head bolts sequentially in four stages.
- First stage: No. 1 - No. 10 - 20 Nm
- Second stage: No. 1 - No. 10 - 49 Nm
- Third stage: No. 1 - No. 0 - 67 Nm
- Fourth stage: No. 1, No. 2 - 67 Nm
Tightening sequence for cylinder head bolts
4. Install the intake manifold, and tighten the nuts in a diagonal sequence in two or three steps, starting from the middle.
- Always use a new intake manifold gasket.
5. Install the exhaust manifold, and tighten the nuts in a diagonal sequence in two or three steps, starting from the middle.
- Always use a new exhaust manifold gasket.
6. Install the exhaust manifold bracket, then install the exhaust pipe and bracket, and then install the cover.
7. Install the timing belt.
8. Adjust the clearance in the valve drive.
9. Install the cylinder head cover gasket into the groove of the cylinder head cover. Place first in the camshaft gaps, then insert into the groove along the entire perimeter.
Attention.
- Before installing the cylinder head cover gasket, completely clean the oil seal and groove.
- When installing, make sure that the cylinder head cover gasket is placed securely without gaps or interruptions.
10. Apply "liquid" gasket to the cylinder head cover gasket at the four corners.
Attention:
- Use Liquid Gasket No. OY740-99986 or 08C70-X0134S.
- Check that contact surfaces are clean and dry before use "liquid" gaskets
- Install the lid within five minutes after application "liquid" gaskets Otherwise, remove any traces of the old gasket and reapply it.
- After assembly, wait at least 20 minutes before filling the engine with oil.
11. When installing the cylinder head cover, support the cylinder head cover gasket in the groove.
Install the spark plug seal onto the spark plug tube. Once the cylinder head cover is installed on the cylinder head, move the cover back and forth a little until it is completely installed.
Attention:
- Before installing the cylinder head cover, clean the contact surfaces of the cylinder head.
- Do not touch the parts where the thin gasket was applied (applied).
- Be careful not to damage the spark plug seal when installing the cylinder head cover.
- Visually check the spark plug seal for damage.
- Replace the washer when it is damaged.
12. Tighten the nuts in two or three steps. At the final stage, tighten all bolts in sequence to 9.8 Nm.
Attention. After assembly, wait at least 20 minutes before filling the engine with oil.
13. After installation, check that all tubes, hoses and connectors are installed correctly.