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 A/C system: Remove the cover, remove the nut and remove the battery bar from the alternator. Disconnect the block from the generator.
4. Models with air conditioning system: Remove the upper and lower alternator mounting bolts and remove the alternator.
5. Air Conditioning Models: Remove the nut and 2 bolts securing the heat shield to the exhaust manifold and remove the heat shield.
6. Models with air conditioning system: Remove the bolt securing the upper bracket securing the alternator to the cylinder head and remove the bracket.
7. Disconnect the block 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 controller.
11. Disconnect the connector from the injector harness.
12. Temporarily install the gears on the camshafts, screw in the mounting bolts, but do not tighten them.
13. Using tool LRT-12-182, rotate the camshafts to gain access to the cylinder head bolts located under the inductive shaft positioners.
14. In the sequence shown in the figure, loosen the cylinder head bolts.
15. Take out bolts of fastening of a head of cylinders and expand them in that order in which they were on a head of cylinders.
16. Remove and dispose of the cylinder head gasket.
WARNING: Removing the cylinder head bolts will result in "wedging" crankshaft. For this reason, the operations associated with the rotation of the crankshaft should be limited as much as possible. Do not rotate the crankshaft until the LRT-12-144 cylinder liners are installed.
17. Determine the type of installed pins: remove the nylon pins and install steel ones.
18. Install the LRT-12-144 cylinder liner mounts to the cylinder block and secure them with the cylinder head mounting bolts. The base of the cylinder liners must not protrude above the cylinder surface.
ATTENTION: The bolts used must be screwed into the same sockets in which they were on the assembled engine.
Installation
1. Turn out bolts from fastenings of liners of cylinders LRT-12-144 and remove fastenings.
CAUTION: Store the cylinder head bolts in the order in which 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. Be convinced of absence of damages on the bottom plane of a head of cylinders and on the top plane of the block of cylinders. Particular attention should be paid to the condition of the lower plane of the cylinder head.
4. Check that the channels of the cooling system and the lubrication system are clean.
5. Check the flatness of the cylinder head for warping by laying a straight edge along the directions shown in the figure.
TECHNICAL CHARACTERISTICS, Engine - gasoline K1.8.
NOTE: The underside of the cylinder head may be ground as long as the head height remains within acceptable limits.
6. Wash the cylinder head bolts and wipe them dry.
7. Apply a thin coat of oil to the threaded portion of the bolts and their headrests.
8. Carefully insert the bolts into their sockets in the order in which they were on the assembled engine, DO NOT RESET THE BOLT INTO THE SOCKET. Hand-tighten each of the bolts into the oil distribution cover.
9. Measure the distance 'A' from the head of the bolt to the top plane of the cylinder block as shown in the figure:
- 97 mm: bolts are recyclable
- Above 97 mm: new bolts must be used
10. If the nylon pins were removed, then you need to clean their nests and put new, steel pins in the cylinder block.
11. The protrusion of the pins should be between 10 and 11 mm.
12. Install a new, dry head gasket to the cylinder block.
13. With the help of a partner, place the cylinder head on the block, making sure that it hits 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 tool LRT-12-182, rotate the camshafts to gain access to the cylinder head bolts located under the inductive shaft positioners.
17. Carefully insert the bolts into their sockets in the order in which they were on the assembled engine, DO NOT RESET THE BOLT INTO THE SOCKET. Tighten the bolts by hand.
18. In the sequence shown in the figure, tighten the cylinder head bolts:
- Stage 1: 20 Nm.
- Stage 2: -180°.
- Step 3: Turn 180°.
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 sensors (IAT), throttle position (TR), coolant temperature (EATING) and idle speed controller (IACV). Connect the connector to the injector harness.
23. Models with air conditioning system: Install the alternator mounting bracket, screw in the bolt and tighten it to a torque of 25 Nm.
24. Models with air conditioning system: Install the heat shield on the exhaust manifold. Screw on the nut and tighten it to 25 Nm, screw in the bolts and tighten them to 10 Nm.
25. Models with air conditioning system: 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 system: Connect the battery bus bar to the alternator, screw on the nut and tighten it to 8 Nm.
27. Models with air conditioning system: Connect the connector to the generator.
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