| 1. Before installing the appropriate scraper to clean the mating surfaces of the cylinder head and cylinder block from the remnants of lining. Pay attention to the fact that the dirt does not hit the hole of the cylinder. Holes close cloth. |
| 2. Check for oil in the holes for the screws of the cylinder head, if necessary, to remove. To do this, enter the holes clean cloth and collect the oil. |
A warning  If the oil remains in the openings when tightening the bolts the cylinder block may be damaged.
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 | 3. Check the steel ruler cylinder head for flatness. Nonflatness checked steel ruler and petal probe across the surface of the cylinder head. Irregularities should not exceed 0.1 mm. |
A warning If the sealing surfaces of the cylinder head will be further developed, the minimum allowable size of the adjustment should not be underestimated (see. Subsection 2.10.3).
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 | 4. Cylinder heads with gaps between the valve seats and valve seat rings, and the first thread by threading the spark plug can be used further without reducing service life and bulkhead if gaps do not exceed the maximum permissible value of a = max 0,5 mm . |
| 5. Cylinder head gasket replace always. |
| 6. Signature "oben" should point to the cylinder head. Cylinder head gasket set without hermetic so that not one hole was not closed. |
| 7. Crank for the pulley so that all pistons were about the same height. |
| 8. Install the cylinder head, paying attention while the guide pins into the cylinder. If necessary, set in both of the outer openings to the inlet side of the new guide pins. Pay attention to the fact that the camshaft is in TDC position for cylinder 1 (see. Subsection 2.5.2.1). |
| 9. Install all 10 cylinder head bolts with lining washers and tighten by hand. Bolts cylinder head is always replaced. |
A warning Tighten the cylinder head bolts to make a great foresight. Before tightening the bolts, check the accuracy of the torque wrench. Cylinder head bolts are tightened to the engine is cold.
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| 10. The cylinder head bolts are tightened with a torque wrench in sequence from 1 to 10 in two steps: first with a force of 40 Nm, and then - 60 Nm. This is followed by more stringent tightening wrench: 1/2 turn (180 ?�). Allowed additional tightening 90 ?� x2 (two times 90 ?� each). |
| 11. When tightening the cylinder head bolts can be estimated rotation angle. Set wrench handle along the engine and turn the key in one motion to the position of the handle across the motor (1/4 turn, 90 ?�). Turn on - to the position of the handle back along the engine. |
A warning Tightening the cylinder head bolts on the warm engine within the service or after repair is not allowed.
When replacing the cylinder head with camshaft installed, it is necessary after the installation of the cylinder head lubricate the interface between the bucket tappets and the cam surface.
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| 12. Install the crankshaft to TDC for cylinder 1. |
| 13. Screw the back casing of a gear belt. |
| 14. Screw on camshaft gear and a tension roller of a gear belt. |
| 15. Install the timing belt. |
| 16. Install the cylinder head cover with maslootboynikom and new seals and tighten to 10 Nm. |
| 17. Install the top casing of a gear belt. |
| 18. Screw the support of the generator to the cylinder head. |
| 19. Tighten the V-belt (see. Subsection 2.12.1). |
| 20. Install the exhaust pipe to the exhaust manifold (see. Subsection 2.19.1). |
| 21. Install the mudguard of a motor compartment. |
| 22. To remove the car from the backups. |
| 23. Screw the tube sampling of exhaust gases to the exhaust manifold and cylinder head. |
| 24. Screw the cover of the exhaust manifold. |
| 25. Attach the air hose to the air heating the receiving housing. |
| 26. Install an air hose between the air filter and throttle body together with the valve of stabilization of idling. |
| 27. Attach the wire throttle control on the throttle and stop. |
| 28. Pull the cable harness through the engine intake manifold. |
29. Connect the wiring:
- Plug a potentiometer;
- Plug the throttle potentiometer;
- Multi-compound injection valves;
- Plug valve of stabilization of idling;
- Plug valve cold start;
- Plug connection for lambda probe under the car, on the bracket mounted units to the right;
- Plug the pressure sensor on the steering gear power steering, if any;
- Oil pressure sensor connector on the left end side of the cylinder head;
- A wire of "weight" from the cylinder head cover to the intake manifold. |
A warning Electric wires secured to the same places and the new cable clamps.
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| 30. Push the spark plug wires. |
31. Attach the vacuum hoses:
- On the throttle warming the air receiver, the solenoid valve of a tank with the activated carbon, the control unit Digifant;
- The return valve for brake booster. |
| 32. Fit the fuel line (black) on the valve cold start and fuel distribution, fix collars. |
| 33. Fit the fuel return pipe (blue) on the fuel distributor and secure the clamp. |
| 34. Screw fitting the coolant hoses to the cylinder head. |
| 35. Fill the coolant. Always replace the coolant. |
| 36. Connect a wire of "weight" (-) to the battery. Enter anti-theft code, program the radio stations and set the clock. |
A warning The battery connected only when the ignition is switched off, otherwise the control unit fuel injection system fails.
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| 37. Check the engine oil level. If the cylinder head gasket was faulty, replace the engine oil and filter. |
| 38. Warm up the engine to operating temperature. Again, check the coolant level and leaks. |
| 39. Check the ignition timing (see. Subsection 2.14.6). |
| 40. Check the idle speed and CO content (see. Subsection 2.18.1). |
| 41. Check the compression pressure (see. Subsection 2.11). |
