Cylinder head, timing adjustment

Gas distribution system

Cylinder head bolt tightening sequence

Installation of a gas distribution system

The location of the camshaft groove when installing the cylinder head

Before installing the head, make sure that the groove at the end of the camshaft eccentric is horizontal (parallel to the bottom plane of the cylinder head), and the larger part of the eccentric is directed upwards.

Attention! The contact surfaces of the cylinder block gasket and the head must be smooth, clean, without scratches or damage. Check the condition of the bottom surface of the cylinder head, this surface cannot be repaired (not regrindable).

1. Measure the protrusion of the pistons above the upper plane of the cylinder block.

2. Depending on the protrusion of the pistons, select the appropriate thickness of the head gasket (see subsection 3.2.1.2.2).

3. Install the head gasket on the cylinder block so that the side marked "TOP" was on top.

4. Install the head to the cylinder block.

5. Insert the mounting bolts into the corresponding holes in the cylinder head.

Attention! When installing the cylinder head, use new mounting bolts.

6. Tighten the cylinder head bolts to the correct torque (see subsection 3.2.1.2.9) in the appropriate sequence (see fig. Cylinder head bolt tightening sequence).


7. In later versions of the 1.8 dm³ engine, a different type of cylinder head bolts are used, which have M12 threads and Torx T70 heads. These bolts should be tightened in the same sequence as the old style bolts (see fig. Cylinder head bolt tightening sequence) the following points:

• 1 stage: 10 Nm;
• Stage 2: 100 Nm;
• Step 3: unscrew the bolt "1" 180°;
• Step 4: Tighten the bolt "1" torque 70 Nm;
• Step 5: Tighten the bolt "1" by an additional 120°.
• Step 6: Tighten as described above (steps 3–5) other bolts in the correct tightening sequence.

8. Screw the glow plugs into the cylinder head, tighten them to the correct torque, and connect their electrical wires.

9. Screw the injectors into the cylinder head together with new thermal insulation washers, with the convex side towards the head.

10. Install the rear right casing of the timing system drive with the tensioner pulley.

11. Install rear left cowl with middle pulley. Check whether the rubber ring of the flexible pipe is in its place on the casing.

12. Install the camshaft pulley and insert the tool (1) (see fig. Installation of a gas distribution system).

13. Check if the engine crankshaft touches the mandrel (3) in the TDC position of the piston of the 1st cylinder.

14. Install a new timing belt for the timing system.

15. Tighten the timing belt as follows. Loosen the bolt securing the pulley to the camshaft, then unscrew the idler pulley bolt half a turn. The tensioner roller will move to the timing belt under the influence of the spring, and then tighten all the above bolts.


16. Remove all installation tools.



17. Turn the crankshaft two full turns in the direction of its working rotation and install it in the position in which the notch of the fuel pump pulley is in position "12 hours".

18. Rotate the crankshaft in the opposite direction and install the fuel pump pulley notch in position "11 o'clock".

19. Screw the mandrel into the control hole of the cylinder block to set the piston of the 1st cylinder to TDC and carefully rotate the engine crankshaft (in the direction of its working rotation) up to the stop in the mounting mandrel.

20. Insert the camshaft pulley setting tool into the hole provided for it (see fig. Installation of a gas distribution system).

21. Unscrew the bolts securing the middle pulley and tensioner roller by one turn; then push the toothed belt section on the opposite side of the tensioner roller in its direction and release the belt.

22. Tighten all mounting bolts.

23. Remove all installation tools, then screw the plug into the installation mandrel inspection hole in the engine block.

24. Install the timing cover.


25. Install and tension the alternator drive V-belt.

26. Install the water pump drive V-belt.

27. Connect the oil return line from the turbocharger to the engine block.

28. Screw on the front exhaust pipe.

29. Screw the exhaust pipe bracket to the transaxle cross member.

30. Install new gaskets and connect oil supply lines to pump and turbocharger.

31. Connect the vacuum line screwed to the fuel pump to the intake manifold.

32. Check and, if necessary, adjust the valve clearance.

33. Install the cylinder head cover with gasket.

Then follow the rest of the steps in reverse order to the process of removing the cylinder head, paying attention to:

• compliance with the appropriate tightening torques for bolts and nuts;
• installing a new thermostat cover gasket;
• removal of air from the fuel system;
• filling the cooling system and removing air from it;
• checking the tightness of all connections.