Installing the cylinder head

The procedure for installing the cylinder head:

1) Install the crankshaft adjusting labels;

2) remove the starter;

3) remove the cap;

4) Install the plug 999 5451 (Fig. 4.7);

5) Turn the crankshaft clockwise until it stops;

6) Install the new cylinder head gasket;

7) Lubricate the screws with oil;

8) Install the lower half of the cylinder head;

9) Tighten the bolts in three stages in order, moving from the middle to the outside, using a protractor 951 2050 (Fig. 4.8):

- Stage 1 - 20 Nm;

- Stage 2 - 60 Nm;

- Stage 3 - 130 ?�.

10) Replace the coolant pipe with a new gasket;

11) Place the new O-ring in the spark plug;

12) remove the candles first and fourth cylinders;

13) with a roller apply liquid gasket at the top half of the cylinder head. Use a liquid gasket Volvo 1161059-9;

14) Install camshafts. Secure the front part of the shaft by means of brackets 999 5453 and 999 5452 Rear bracket (without extensions) (Fig. 4.9);

15) Replace the top half of the cylinder head;

16) using devices zapressovochnyh 999 5454 (2 pcs.) Push the cylinder head;

17) moving from the middle to the outside, tighten the bolts of the upper half of the torque 17 Nm;

18) Remove the bracket 999 5453 and 999 5454 zapressovochnye devices;

19) using a drift 999 5449, select (press-fit), the ring of the camshaft front oil seal (Fig. 4.10). Lubricate the oil seal ring;

20) Set the camshaft pulleys (Figure 4.11), aligning the timing marks. Screw the two bolts in the camshaft pulley to the ground;

21) replace the camshaft belt (Fig. 4.12), as follows:

- Replace the tensioner / damper and tighten to 25 N ?� m;

- Head of the belt around the camshaft pulley, water pump and pull it over the tensioner pulley;

- Turn out two bolts of a pulley of a camshaft;

- Remove the locking pin from the tensioner / damper;

- Firmly press the belt and double strike it with a plastic hammer in the direction shown by the arrow 1, and twice in the direction of arrow 2;

22) set the third bolt and tighten it to 20 Nm (Fig. 4.13);

23) tighten the bolt of the inner cover of the timing belt;

24) Install the top cover of the timing belt;

25) Remove the bracket 999 5451 with the crankshaft (Fig. 4.14) and put the cork;

26) Install the starter;

27) Remove the bracket 999 5452 with the camshaft;

28) Check the match marks (Fig. 4.15), as follows:

- Rotate the crankshaft by two turns;

- Check the coincidence of adjusting labels on pulleys of cranked and camshafts;

29) set the outer cover of the timing belt;

30) Lubricate packing rings. With the help of the plug set 999 5450 (press-fit), the ring of the camshaft rear oil seal (Fig. 4.16). If at the end of the shaft has signs of wear, the gland ring can be pressed into two mm further;

31) set the reactive arm with a clamp;

32) Install the rotor and the holder;

33) Install the camshaft position sensor (Fig. 4.17) and the diaphragm;

34) Install the spark plug;

35) set the coil (2 pcs.) And wires to the spark plugs;

36) Install an air filter with all the hoses and connectors;

37) Install exhaust manifold;

38) Install the intake manifold and electric;

39) set the engine cooling fan;

40) Install the fuel distribution;

41) set the braided wire connection with weight;

42) Install the exhaust pipe;

43) set the plate under the engine;

44) Fill with coolant and replace oil and oil filter

45) Connect the negative battery cable;

46) Warm up the engine before the opening of the oven and, if necessary, add coolant;

47) Check for leaks.