Note:
- Always put a new gasket under the cylinder head.
- The contact surfaces of the head and cylinder block must be clean.
- Label «UP» (top) on the camshaft pulley should be on top.
- Turn the crankshaft so that the No. 1 cylinder piston is at TDC.
- Clean the oil jet before installation.
- Do not use the top and bottom covers to store removed components.
- Clean the top and bottom covers before installation.
1. Cylinder head dowel pins must be aligned (figure in the right column above).
2. Position the camshaft correctly (see above).
3. Tighten the cylinder head bolts in four steps in sequence:
- 1st pass: (1) - (10) 20 Nm (2.0 kgf/m)
- 2nd pass: (1) - (10) 49 Nm (5.0 kgf/m)
- 3rd pass: (1) - (10) 67 Nm (6.8 kgf/m)
- 4th pass: (1), (2) 67 Nm (6.8 kgf/m)
Note:
- We recommend using a tilt-arm torque wrench. When using a fixed torque wrench, tighten slowly and do not overtighten.
- If the bolt makes any sound when tightening, loosen it and retighten it starting from the 1st pass.
4. Install the intake manifold and tighten the nuts crosswise in two or three passes, starting with the inner nuts.
5. Install the exhaust manifold and tighten the nuts crosswise in two or three passes, starting with the inner nuts.
6. Install the exhaust manifold bracket, then exhaust pipe A and bracket, and then the cover.
7. Put on the timing belt (see above).
8. Adjust valve clearances (see above).
9. Lay a lining under a cover of a head of cylinders in a flute of a cover of a head of cylinders. First lay it in the grooves under the camshaft, then in the groove along the outer edges.
Note:
- Before installing the gasket under the cylinder head cover, carefully clean the groove from the sealant.
- When installing, make sure the cylinder head cover gasket fits securely into place at the corners of the recesses without leaving any gaps.
10. Apply sealant to the cylinder head cover gasket at the four corners of the recesses.
Note:
- Use sealant P/N 08C70 - K0234M, 08C70 - K0334M or 08C70 - X0331S.
- Make sure contact surfaces are clean and dry before applying sealant.
- Do not install components if more than five minutes have passed since the sealant was applied. Instead, apply sealant again, removing traces of the old.
- After assembly, wait at least 30 minutes before filling the engine with oil.
11. When installing the cylinder head cover, hold the gasket in the groove by placing your fingers on the contact surfaces of the camshaft brackets (top semicircular).
Place the spark plug seals on the spark plug tube. After installing the cover on the cylinder head, slightly move the cover so that the gasket under the cylinder head cover is in place.
Note:
- Before installing the cylinder head cover, clean the contact surfaces of the cylinder head with a cloth.
- Do not touch areas where sealant has been applied.
- When installing the cylinder head cover, be careful not to damage the spark plug seal.
- Visually inspect the spark plug seal for damage.
- Replace the washer if it is damaged or fails.
12. Tighten the nuts in two or three passes. On the final pass, tighten all bolts sequentially to 9.8 Nm (1.0 kgf/m).
Note: After assembly, wait at least 30 minutes before filling the engine with oil.
13. After installation, make sure that all tubes, hoses and fittings are installed correctly.