We install the cylinder head after repair, inspection and defect detection
Before installing the cylinder head, set the cylinder pistons to the middle of the stroke.
It is necessary to degrease the seating surfaces of the cylinder head and cylinder block.
Check the presence of the guide bushing on the cylinder block.
Install the Mot104 device or a cut stud on the cylinder block as a second guide.
Install the cylinder head gasket on the cylinder block.
Install the cylinder head.
Unscrew the Mot104 device or a cut stud as a second guide.
Tighten the cylinder head bolts in the sequence shown in Figure 1 to a torque of 20±2 Nm.
After tightening the bolts, tighten all the bolts in the sequence shown by an angle of 240±6˚.
Installing the hydraulic valve lifters (Fig. 2).
Checking the functionality of the hydraulic lifters: - press on the upper part of the hydraulic lifter, if the cylinder is pressed in easily, then the hydraulic lifter may be clogged with resins.
You need to immerse the hydraulic lifter in kerosene or diesel fuel to dissolve the resins.
After this, you need to immerse the hydraulic lifter in oil and check again.
If after this the hydraulic lifter does not become elastic, then the hydraulic lifter is faulty and needs to be replaced.
Installing the valve rocker arms (Fig. 3).
Lubricate the camshaft bearings with engine oil.
Install the camshafts (see How to replace the hydraulic valve lifters of the K4M engine).
Degrease the seating surface of the head and cylinder head cover.
Apply Loctite518 sealant with a roller until it turns reddish.
If sealant gets on the camshaft bearings, be sure to wipe it off.
Install the cylinder head cover.
Tighten the cylinder head cover in the order shown in Figure 6 step by step:
- Stage 1 - bolts 22, 23, 20 and 13 with a tightening torque of 8 Nm (0.8 kgf.m);
- Stage 2 - bolts 1 - 12, 14 - 19, 21 and 24 with a tightening torque of 15 Nm (1.5 kgf.m);
- Stage 3 - loosen bolts 22, 23, 20 and 13;
- Stage 4 - tighten bolts 22, 23, 20 and 13 with a tightening torque of 15 Nm (1.5 kgf.m).
Unscrew the locking bolt of the eccentric cam tappet (1) of the Mot1669 device (see. fig. 7).
Screw in the standard eccentric cam follower lock bolt (2), applying a drop of LoctiteFrenetanch (glue sealant) to its thread.
Tighten the eccentric cam follower lock bolt to 15 Nm.
Apply sealant to the seating surface of the oil separator cover Loctite518 (Figure 8).
Install the oil separator cover.
Tighten the new oil separator mounting bolts in the unthreaded holes, new or old oil separator cover mounting bolts in the threaded holes in the specified order to the required torque (see Figure 9).
Installing the camshaft phase regulator solenoid valve seal using the Mot1513 tool (see Fig. 10) and the electromagnetic valve of the inlet camshaft phase regulator.
Tighten the bolts of the electromagnetic valve of the inlet camshaft phase regulator to a torque of 10 Nm.
Using tool (2) Mot1503, install the cylinder head cover plug (1) (Figure 11).
Apply "Graissrfluore" grease (2 mm wide) to all four ignition coils along the inner circumference of the high-voltage wire cap (Figure 12).
Install the spark plugs. Install the ignition coils in place.
Install the camshaft sensor with a new gasket (Figure 13).
Install the intake manifold gaskets and install the intake manifold.
Tighten the intake manifold in accordance with Figure 14.
Further assembly is carried out in the reverse order of disassembly.
Tightening torques for fasteners when installing the cylinder head:
Unit - Torque Nm
- Cylinder head cover fastening bolts 1 through 12, 14 through 19 and 21 through 24 - 15
- Cylinder head cover fastening bolts 13, 20, 22, 23 - 15
- Eccentric cam follower lock bolt - 15
- New oil separator mounting bolts in unthreaded holes - 15
- New or old oil separator mounting bolts in threaded holes - 10
- Intake camshaft phase regulator solenoid valve bolt - 10
- Spark plugs - 25-30
- Ignition coil mounting bolts - 15
- Camshaft sensor mounting bolt - 10
- Intake manifold mounting bolts - 9
- Timing belt idler roller mounting bolt - 45
- Timing belt tension roller axle mounting nut - 27
- TDC locking pin hole plug - 20
- Timing drive upper cover mounting bolts - 41
- Throttle valve unit mounting bolts - 11
- Lifting eye mounting bolts (flywheel side) - 10
- Lifting eye mounting bolts (timing drive side) - 35