1. Clean the surface of the head and cylinder block.
2. Install a new cylinder head gasket and dowel pins on the cylinder block.
Note: Always use a new cylinder head.
3. Make sure the crankshaft keyway is pointing up.
4. Put the block head on the cylinder block,
5. Measure the diameter of the cylinder head bolt at two points.
6. If the diameter of the bolt is less than 8.6 mm, replace the bolt.
7. Apply fresh engine oil to the threads and under the bolt heads.
8. Tighten the cylinder head bolts in the sequence shown in the figure. Do not overtighten the bolts. If the bolt makes a sound when tightening, unscrew it and retighten it.
- Tightening torque - 29 Nm
9. Tighten all bolts by 130°.
Note: if the bolts have been tightened to a greater angle; turn them inside out and repeat, procedures starting from step "5".
10. Install the timing chain guide bolt.
11. Install the chain on the camshaft sprocket, aligning the marks. Install the sprocket onto the camshaft.
12. Fix the camshaft with a 27 mm key and tighten the bolt.
- Tightening torque - 56 Nm
13. Temporarily install the crankshaft pulley,
14. Apply engine oil to the contact surface of the tensioner through the oil return hole in the cylinder head.
15. Fix the crankshaft pulley and install the key on the camshaft sprocket bolt.
16. Turn the camshaft clockwise until the chain tensioner is compressed, then remove the M6x1.0 mm bolt.
Note:
- The torque when turning the camshaft bolt must not exceed 56 Nm.
- Do not turn the camshaft counterclockwise.
17. Check up a forward epiploon of a cranked shaft on deterioration. If the seal is damaged, replace it.
18. Remove the sealant from the surface of the chain cover, bolts and bolt holes.
19. Clean the contact surfaces of the timing chain cover.
20. Apply sealant to the contact surfaces of the cylinder block and timing chain cover.
Note:
- Apply a continuous bead of sealant with a diameter of 1.5 mm to the places indicated "A".
- Apply a large amount of sealant with a diameter of 3 mm to the chain cover in the places indicated "IN".
- Parts must be installed within the time specified in the instructions for use of the sealant. Otherwise, the sealant must be removed and reapplied.
21. Apply sealant to the part of the chain cover in contact with the oil pan.
Note:
- Apply a continuous bead of sealant with a diameter of 1.5 mm in the places indicated "A".
- Apply a 5 mm diameter bead of sealant to the area marked "IN".
- Parts must be installed within the time specified in the instructions for use of the sealant. Otherwise, the sealant must be removed and reapplied.
22. First install the face of the chain cover on the oil pan, and then install the cover on the cylinder block.
Note: when installing the cover, do not move its lower part along the contact surface of the oil pan.
A - timing chain cover,
B - oil pan,
C - cylinder block.
23. Install the wire retainer and connect the crankshaft position sensor connector.
24. Install the engine front bracket and ground wire.
25. Install the crankshaft pulley.
26. Install the cylinder head cover,
27. Install the water pump pulley.
28. Install the intermediate roller.
29. Install the alternator bracket set bolt.
30. Install the accessory drive belt and adjust its tension.
31. Install the O-ring connecting tube.
32. Install the coolant bypass flank.
A - connecting tube,
B - O-ring,
C - coolant bypass hose.
33. Install the wire holder "A", ground wire "IN", wire clamp "WITH", coolant bypass hose "D" and wiring harness "E".
34. Install the fuel manifold.
35. Install the exhaust manifold.
36. Install the intake manifold.
37. Install the heater hose.
38. Install the upper and lower radiator hoses.
39. Connect the cleaning hose "A", coolant bypass hose "IN", throttle body connectors "WITH" and evaporative emission filter "D".
40. Install the air filter assembly.
41. Adjust the valve clearance.
42. Make sure all tubes and connectors are properly connected;
43. Check for fuel leaks. Turn the ignition key to position "ON" (II) (do not start the engine) so that the fuel pump runs for 2 seconds and pressurizes the fuel line. Repeat this operation 2-3 times and check the fuel line for fuel leaks.
44. Fill in coolant and bleed air.
45. Reset the parameters of the crankshaft position sensor and re-enter (see section "Control system").
46. Check up minimum steady frequency of rotation of idling.
47. Check the ignition timing.