Contents: Removal ⬇ Installation ⬇
Removal
1. Disconnect the negative battery terminal.
2. Drain the fluid from the engine cooling system.
3. Loosen the bolt (1) and remove the electromagnetic valve (2) of the intake camshaft phase shifter.
4. Loosen the bolts (2) and remove the plate (1) of the rear opening of the cylinder head.
5. Loosen the mounting bolts and remove the rear cover of the intake camshaft bearing.
6. Mark the intake camshaft bearing caps for proper installation during assembly.
Note: Loosen each bolt one turn at a time until the caps stop springing.
7. Remove the camshaft bearing caps.
8. Remove the intake camshaft.
9. Remove the intake camshaft roller tappets.
Note: Arrange all roller rocker arms and hydraulic lifters in order so that they fit in their proper places during installation.
10. Remove the intake valve lifters.
11. Loosen the bolt (1) and remove the electromagnetic valve (2) of the exhaust camshaft phase shifter.
12. Loosen the mounting bolts and remove the rear cover of the exhaust camshaft bearing.
13. Mark the exhaust camshaft bearing caps for proper installation during assembly.
Note: Loosen each bolt one turn at a time until the caps stop springing.
14. Remove the camshaft bearing caps.
15. Remove the exhaust camshaft.
16. Remove the intake camshaft roller tappets.
Note: Arrange all roller rocker arms and hydraulic lifters in order so that they fit in their proper places during installation.
17. Remove the intake valve lifters.
18. Remove the intake manifold.
19. Remove the exhaust manifold.
20. Remove the upper timing chain guide.
21. Loosen the cylinder head mounting bolts in the specified sequence.
22. Remove the cylinder head (1) with the gasket (2) from the cylinder block.
23. Use a spatula to clean the surfaces of the cylinder block and cylinder head. Be careful not to scratch or damage the contact surfaces.
Attention.
- Use a new spatula each time to clean the cylinder block and cylinder head.
- Do not use mechanical means to clean the joint surfaces.
- Be careful not to create gouges or scratches in the joint surfaces or combustion chamber. The condition of the joint surfaces is important to ensure a tight seal with the gasket. After removing the remains of the old gasket, small depressions may remain on the surface, which will be filled when the new gasket is installed.
When removing the remains of the old gasket, it is necessary to hold the spatula as parallel as possible to the surface being cleaned.
24. Using a nylon brush, clean the threaded holes. If necessary, use solvent and compressed air.
Note: Do not use a tap to clean the threaded holes in the cylinder head.
Caution: When using compressed air to clean holes, wear goggles to protect your eyes.
25. If it is necessary to remove a sheared bolt from the cylinder head, use the EN-38188 kit.
Installation
1. Install the gasket (1) onto the cylinder block (2), paying attention to the locating pin (3) to ensure correct installation of the gasket.
Note: Do not use sealants.
2. Make sure that the piston of the first cylinder is in the top dead center position. To do this, it is necessary that the mark (1) on the balance pulley of the crankshaft coincides with the mark (2) on the oil pump housing.
3. Install the cylinder head.
4. Install new cylinder head bolts.
Note: Always use new cylinder head bolts.
5. Tighten the cylinder head bolts in the specified sequence to a torque of 30 Nm.
6. Tighten the cylinder head bolts another 155° using the EN-45059 tool.
7. Install the front cylinder head bolts (1) and tighten to 35 Nm.
8. Install the exhaust valve lifters into the corresponding seats in the cylinder head, applying clean engine oil to the lifters.
9. Lubricate the ends of the valve stems.
10. Place the roller rocker arms on the ends of the valve stems and on the hydraulic compensators. Apply grease to the rocker arms.
Note: Used roller rocker arms must be installed in their original positions. If the camshaft is to be replaced, the roller rocker arms must also be replaced with new ones.
11. When installing the exhaust camshaft, make sure that its groove (1) is in the 7 o'clock position. The piston of the first cylinder should be in the top dead center position of the exhaust stroke, and the crankshaft key in the 12 o'clock position.
12. Install the exhaust camshaft (1) on the roller rocker arms in the main bearings. Lubricate the camshaft with engine oil.
13. Before installing the camshaft main bearing caps, rotate the seals in the grooves of the first camshaft journal so that the joint line (1) is approximately at the 12 o'clock position.
14. Make sure that the groove (1) on the exhaust camshaft is approximately at the 7 o'clock position.
15. Install the camshaft covers (1).
16. Apply engine oil to the bolts (2) and tighten them by hand three turns, then tighten the bolts to a torque of 10 Nm.
17. Apply a bead of sealant with a diameter of 2.5 mm to the cylinder head at the location where the rear cover of the exhaust camshaft bearing is installed, without extending the sealant to a distance of "a" = 2 mm from the edge, as shown in the figure.
Note
It is very important during installation to ensure that the rear camshaft bearing cover and cylinder head are properly aligned so that they are level. To do this:
- Ensure that all sealant residue is removed from the components and that the sealing surfaces are clean and free of old sealant residue.
- Install and align the rear camshaft bearing cover within 20 minutes after applying the sealant.
18. Install the rear cover of the exhaust camshaft bearing and tighten the mounting bolts evenly, first to 5 Nm, then to 10 Nm. Loosen the bolts by 120°, then finally tighten to 10 Nm.
19. Remove all excess sealant from the brake booster pump bore (1). Make sure the bore and mating surfaces are clean. Do not allow excess sealant to remain on the cylinder head or mating surfaces.
20. Install the intake valve lifters, applying clean engine oil to them.
21. Lubricate the ends of the valve stems.
22. Place the roller rocker arms on the ends of the valve stems and on the hydraulic compensators. Apply grease to the rocker arms.
Note: Used roller rocker arms must be installed in their original positions. If the camshaft is to be replaced, the roller rocker arms must also be replaced with new ones.
23. When installing the intake camshaft, make sure that its groove (1) is approximately at the 5 o'clock position. The piston of the first cylinder should be at the top dead center position of the exhaust stroke, and the crankshaft key at the 12 o'clock position.
24. Install the intake camshaft on the roller rocker arms in the main bearings. Lubricate the camshaft with engine oil.
25. Before installing the camshaft main bearing caps, turn the seals in the grooves of the first journal of the camshaft so that the joint line (!) is approximately at the 12 o'clock position.
26. Make sure that the groove (1) on the intake camshaft is approximately at the 5 o'clock position.
27. Install the camshaft covers (1).
28. Apply engine oil to the bolts (2) and tighten them by hand three turns, then tighten the bolts to a torque of 10 Nm.
29. Apply a 2.5 mm diameter bead of sealant to the cylinder head where the exhaust camshaft bearing rear cover is installed:
- Distance "a" = 5 mm.
- Where the lid ends, extend the bead of sealant approximately 4 mm beyond its edges.
- Distance "c" = 32 mm.
- Distance "b" -20 mm.
Note
It is very important during installation to ensure that the rear camshaft bearing cover and cylinder head are properly aligned so that they are level. To do this:
- Ensure that all sealant residue is removed from the components and that the sealing surfaces are clean and free of old sealant residue.
- Install and align the rear camshaft bearing cover within 20 minutes after applying the sealant.
30. Install the sixth rear camshaft cover. Tighten the mounting bolts evenly first to 5 Nm, then to 10 Nm. Loosen the bolts by 120°, then finally tighten to 10 Nm.
31. Remove all excess sealant from the fuel pump drive bore (1). Make sure the bore and mating surfaces are clean. Do not allow excess sealant to remain on the cylinder head or mating surfaces.
32. Remove excess sealant from the fuel pump mounting surface.
33. Make sure that the mounting surfaces are clean, then install the cylinder head rear opening plate (1) and tighten the bolts to 10 Nm.
34. Install the upper timing chain guide.
35. Install the exhaust manifold.
36. Install the intake manifold.
37. Install the intake camshaft phase shifter electromagnetic valve.
38. Install the exhaust camshaft phase shifter electromagnetic valve.
39. Fill the engine cooling system.
40. Connect the negative terminal of the battery.
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