Installing Cylinder Head

Cylinder head, installing

Note:
• Always replace cylinder head bolts when assembling.
• Replace self-locking nuts.
• Always replace bolts that are tightened to a specified angle.
• If repairing, carefully remove any remains of gasket material from the cylinder head and cylinder block. Make sure that no long scores or scratches are made on the surfaces.
• Carefully remove any remaining emery and abrasive material.
• Remove new cylinder head gasket from packaging, just before installation.
• Handle gasket extremely carefully. Damaging the silicone layer or the indented area will lead to leaks.
• No oil or coolant must be allowed to remain in the blind holes for the cylinder head bolts in the cylinder head.
• Ensure fuel hoses are tight.




- Before positioning cylinder head, set crankshaft and camshaft to TDC of No. 1 cylinder.




- Unscrew bolts -1- and -2- on turbocharger bracket (about 2 full turns each) to avoid stressing when installing the cylinder head.




- Place cylinder head gasket in position.
- Note position of centralizing pins in cylinder block -arrows-.
- Check installation position of cylinder head gasket.
- The Part No. should be legible from the intake side.
- Place cylinder head in position.
- Insert cylinder head bolts and tighten by hand.




- Tighten cylinder head bolts in two stages in sequence shown as follows:
- Stage 1: 40 Nm
- Stage 2: additional 1/2 turn (180°) using rigid wrench (in two 1/4 turns (90°) if necessary).

Note: It is not necessary to re-tighten cylinder head bolts after repairs have been performed.

- Install turbocharger with new gasket and bolt bracket to cylinder block.
- Install toothed belt (adjust valve timing). Service and Repair

Note: Follow all instructions for removing and installing toothed belt.

- Install cylinder head cover.
- Installing ribbed belt and tensioning element. Service and Repair
- After connecting battery terminals, enter anti-theft code for radio
Refer to Radio operating instructions
- Close electric windows in front doors all the way to their top positions using electric switches.
- Operate all electric window switches again for at least one second in the "close" direction to activate the automatic one - touch function.
- Set clock to correct time.
- Perform adaptation of throttle valve control part.
- Check DTC memory.

Note: DTCs will be stored in the memory because connectors have been unplugged. Therefore, check and erase DTC memory after installing the engine.

Electrical connections and routing:
Refer to Electrical Wiring Diagrams, Troubleshooting & Component Locations binder, Or equivalent