Note: Always replace the cylinder head gasket and bolts with new ones.
Attention:
- It is necessary to use protective equipment (gloves, glasses 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, which will cause engine damage.
- Do not scratch the aluminum contact surfaces, any damage to the contact surfaces may cause leaks.
- To ensure the required tightness, the gasket surfaces must be clean and free of grease (keep fingerprints away)
1. Clean the contact surfaces with a strong cleaning agent 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 feeler gauges, check the deformation of the cylinder head contact surface. Maximum permissible surface deformation: no more than 0.05 mm.
Note: The cylinder head surface is not re-sharpened.
3. Install the new cylinder head gasket, centering it on the two mounting pins.
4. Place the pistons in the middle position to prevent the valves from contacting the piston crowns 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. Tighten the cylinder head mounting bolts to a torque of 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: Ensure that the cylinder head bolts are correctly tightened to 25 Nm.
8. Tighten the cylinder head bolts in the sequence shown in the figure to an angle of 270°±10°.
9. Install the vacuum lines of the vacuum pump.
10. Install the water hoses to the cooling system chamber.
11. Install the turbocharger.
12. Install the exhaust gas cooler.
13. Install the EGR system components.
14. Install the turbocharger exhaust outlet pipe.
15. Install the rocker cover.
16. Connect the high pressure fuel pump connectors.
17. Connect the glow plug connectors.
18. Install the fuel rail (see chapter "Power supply system").
19. Install the fuel injectors (see chapter "Power supply system").
20. Install the fuel return line (see chapter "Power supply system").
21. Install high-pressure fuel lines between the fuel rail and the injectors (see chapter "Power supply system").
22. Install high-pressure fuel lines between the high-pressure fuel pump and the fuel rail (see chapter "Power supply system").
23. Install the timing belt of the gas distribution mechanism drive.
24. Install the damper valve.
25. Connect the coolant temperature sensor connector.
26. Remove the lower crossmember (Mot. 1672) from the vehicle.
27. Connect the battery.
28. Fill and bleed the engine cooling system.