Note: Be sure to replace the gasket and cylinder head bolts with new ones.
Attention:
- Be sure to use protective equipment (gloves, goggles and respirators).
- Thoroughly clean the cylinder head to prevent foreign bodies from entering the oil lines. Failure to do so may result in clogged oil lines, resulting in engine damage.
- Do not scratch the aluminum contact surfaces, any damage to the contact surfaces may cause leakage.
- The gasket surfaces must be clean and free from grease to ensure proper sealing (prevent fingerprints)
1. Clean the contact surfaces with a strong cleaner to dissolve any gasket residue. To do this, apply the cleaning agent to the surfaces to be cleaned, wait about ten minutes, and then remove the residue with a wooden or plastic spatula.
2. Using a straightedge and a set of flat feelers, check the deformation of the contact surface of the cylinder head. Maximum permissible deformation of the surface: no more than 0.05 mm.
Attention: The surface of the cylinder head is not regrinded.
3. Install a new cylinder head gasket by centering it over the two dowel pins.
4. Place the pistons in the middle position to prevent contact of the valves with the bottoms of the pistons when tightening the cylinder head.
Caution: To ensure proper tightening of the cylinder head bolts, use a syringe to remove any oil that may be in the cylinder head mounting holes.
5. Install the cylinder head.
Caution: Do not lubricate new cylinder head bolts.
6. Fit the cylinder head bolts to 20 Nm in the sequence shown in the figure.
7. Tighten the cylinder head bolts in the sequence shown in the figure to a torque of 25 Nm.
Note: Make sure the cylinder head bolts are correctly tightened to 25 Nm.
8. Tighten the cylinder head bolts in the sequence shown in the figure by an angle of 270°±10°.
9. Install the vacuum lines for the vacuum pump.
10. Install the water hoses on the cooling chamber.
11. Install the turbocharger.
12. Install the exhaust gas cooler.
13. Install the components of the exhaust gas recirculation system.
14. Install the turbocharger exhaust outlet.
15. Install rocker cover.
16. Connect the high pressure fuel pump connectors.
17. Connect the glow plug connectors.
18. Install the fuel rail (see chapter "Supply system’’).
19. Install fuel injectors (see chapter "Supply system").
20. Install fuel return line (see chapter "Supply system").
21. Install high pressure fuel lines between fuel rail and injectors (see chapter "Supply system").
22. Install high pressure fuel lines between high pressure fuel pump and fuel rail (see chapter "Supply system").
23. Install the timing belt.
24. Install damper valve.
25. Connect the coolant temperature sensor connector.
26. Remove the lower traverse (Mot. 1672) from the car.
27. Connect the battery.
28. Fill and bleed the engine cooling system.