Contents: Dismantling ⇩ Installation ⇩
Dismantling
1. Remove the rear timing belt cover.
ENGINE - MODIFICATION K, volume 1.8, Front exhaust camshaft oil seal, Rear timing belt cover.
2. Remove the valve cover with gasket.
ENGINE - MODIFICATION K, volume 1.8, Piston group, Valve cover gasket.
3. Models with air conditioning: Remove the cover, unscrew the nut and remove the battery busbar from the alternator. Disconnect the connector from the alternator.
4. Models with air conditioning: Remove the upper and lower generator mounting bolts and remove the generator.
5. Models with air conditioning: Remove the nut and 2 bolts securing the heat shield to the exhaust manifold and remove the heat shield.
6. Models with air conditioning: Loosen the bolt securing the upper generator mounting bracket to the cylinder head and remove the bracket.
7. Disconnect the connector from the coolant temperature sensor.
8. Disconnect the connector from the throttle position sensor.
9. Disconnect the connector from the intake air temperature sensor.
10. Disconnect the connector from the idle speed control valve.
11. Disconnect the connector from the injector wiring harness.
12. Temporarily install the gears on the camshafts, screw in the mounting bolts, but do not tighten them.
13. Using the LRT-12-182 tool, rotate the camshafts to gain access to the cylinder head mounting bolts located under the inductive camshaft position sensors.
14. Loosen the cylinder head mounting bolts in the sequence shown in the figure.
15. Remove the cylinder head mounting bolts and arrange them in the order in which they were located on the cylinder head.
16. Remove and discard the cylinder head gasket.
CAUTION: Removing the cylinder head mounting bolts will cause the crankshaft to "stick". For this reason, operations involving crankshaft rotation should be limited as much as possible. Do not rotate the crankshaft until the LRT-12-144 cylinder liner fasteners have been installed.
17. Determine the type of pins installed: nylon pins should be removed and steel ones installed.
18. Install the LRT-12-144 cylinder liner fasteners on the cylinder block and secure them with the cylinder head fastening bolts. The base of the cylinder liner fasteners should not protrude above the cylinder bore.
CAUTION: The bolts used must be screwed into the same sockets in which they were located on the assembled engine.
Installation
1. Remove the bolts from the LRT-12-144 cylinder liner fasteners and remove the fasteners.
CAUTION: Store the cylinder head bolts in the order they were on the assembled engine. Do not rotate the crankshaft after removing the cylinder liner fasteners.
2. Clean the mating surfaces of the cylinder head and cylinder block.
3. Check for damage on the lower surface of the cylinder head and on the upper surface of the cylinder block. Particular attention should be paid to the condition of the lower surface of the cylinder head.
4. Check that the cooling system and lubrication system passages are clean.
5. Check the cylinder head plane for warpage by placing a straight edge along the directions shown in the figure.
TECHNICAL SPECIFICATIONS, Engine - petrol K1.8.
NOTE: Grinding the bottom surface of the cylinder head is permitted provided that the head height remains within acceptable limits.
6. Wash the cylinder head mounting bolts and wipe them dry.
7. Apply a thin layer of oil to the threaded portion of the bolts and their heads.
8. Carefully insert the bolts into their sockets in the order they were on the assembled engine, DO NOT DROP THE BOLT INTO THE SLOT. Screw each bolt into the oil distributor cover by hand.
9. Measure the distance 'A' from the bolt head to the top plane of the cylinder block as shown in the figure:
- 97mm: Bolts are reusable
- Over 97mm: New bolts must be used
10. If the nylon pins were removed, then you need to clean their sockets and install new steel pins in the cylinder block.
11. The protrusion of the pins should be from 10 to 11 mm.
12. Install a new, dry head gasket onto the cylinder block.
13. With the help of a partner, place the cylinder head on the block, making sure that it lands on the pins.
14. Wipe the camshaft gears.
15. Temporarily install the gears on the camshafts, screw in the mounting bolts, but do not tighten them.
16. Using the LRT-12-182 tool, rotate the camshafts to gain access to the cylinder head mounting bolts located under the inductive camshaft position sensors.
17. Carefully insert the bolts into their sockets in the order they were on the assembled engine, DO NOT DROP THE BOLT INTO THE SLOT. Tighten the bolts by hand.
18. Tighten the cylinder head mounting bolts in the sequence shown in the figure:
- Stage 1: 20 Nm.
- Stage 2: -180°.
- Step 3: 180° turn.
CAUTION: Do not turn the bolts 360° in one go.
19. Remove the camshaft gears.
20. Install the rear timing belt cover.
ENGINE - MODIFICATION K, volume 1.8, Front exhaust camshaft oil seal, Rear timing belt cover.
21. Install the valve cover gasket.
ENGINE - MODIFICATION K, volume 1.8, Piston group, Valve cover gasket.
22. Connect the connectors of the intake air temperature (IAT), throttle position (TP), engine coolant temperature (ECT) sensors and the idle air control valve (IACV) connector. Connect the connector to the injector harness.
23. Models with air conditioning: Install the generator mounting bracket, screw in the bolt and tighten it to 25 Nm.
24. Models with air conditioning: Install the heat shield on the exhaust manifold. Fit the nut and tighten it to 25 Nm, fit the bolts and tighten them to 10 Nm.
25. Models with air conditioning: Install the generator, screw in the upper and lower mounting bolts and tighten them to a torque of 45 Nm.
26. Models with air conditioning: Connect the battery busbar to the alternator, screw on the nut and tighten it to 8 Nm.
27. Models with air conditioning: Connect the connector to the generator.
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