Removing the cylinder head
Loosen the bolts in 2 or 3 steps in the sequence shown in the figure, and then remove the cylinder head assembly.
Attention! When loosening the cylinder head bolts, be careful not to damage or deform the spark plug guide tubes as they are not supplied separately.
Installing the cylinder head gasket
Using a special scraper, remove the remnants of the old cylinder head gasket from the cylinder block.
Attention! When carrying out this operation, do not allow gasket material or other foreign particles to enter the channels of the cooling system and lubrication system.
Degrease adjacent gasket surfaces.
At installation check up coincidence of all openings on a lining and a head of cylinders.
Verify that the correct engine identification mark is on the new cylinder head gasket.
Lay the cylinder head gasket on the cylinder block with the identification mark facing up, so that it is located on the side of the exhaust valves.
When installing the cylinder head bolts, make sure the length «A» of each bolt is within the allowable value.
If length «A» exceeds the limit value, the bolts must be replaced.
Limit value «A»: 99.4 mm.
Lubricate the threads and washers of the cylinder head bolts with a thin layer of engine oil.
Note. If the cylinder head bolt washer has been replaced, install it with the chamfered side up as shown.
Tighten the bolts according to the procedure below.
Note. Always turn the bolt to a strict 90°angle. Otherwise, the cylinder head bolt may be loosened (the reliability of the gas joint will not be ensured).
Note. If the bolt is turned more than 90°, loosen it completely and repeat all operations starting from step 1.
High pressure fuel hose installation
Lubricate the O-ring with a little fresh engine oil.
Attention! Do not allow oil to enter the fuel manifold.
Slightly turning the fuel hose flange to the right or left, carefully insert it into the fuel manifold to prevent damage to the gasket. After installation, check that the hose turns smoothly in the fuel manifold.
If the hose flange sticks when turning, the cause may be a damaged O-ring. Detach the flange (complete with hose) from fuel
manifold and check the gasket for damage, then reinsert it and check for smooth rotation.
Installing camshaft sprockets
Secure the camshaft sprockets against rotation using a special fork holder and special bolts.
Wrap bolts of fastening of an asterisk of camshafts the nominal moment.
Tightening torque: 89±9 Nm.
Install the coolant inlet pipe and thermostat housing assembly.
Install the timing belt top cover.
Install the exhaust manifold.
Install the air filter assembly.
Fill with coolant and engine oil.
Adjust the tension of the accessory drive belt.
Adjust the accelerator pedal cable.