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 coating 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 block.
- Ensure fuel hoses are tight.
- Before positioning cylinder head, set crankshaft and camshaft to TDC of No. 1 cylinder.
- Remove 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 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: Torque a further 180° (1/2 turn) with a rigid wrench.
It is permissible to torque by 2 x 90°.
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. Refer to Cylinder head, installing .
- Install toothed belt (adjust valve timing). Refer to Installing (adjusting valve timing) .
NOTE:
Follow all instructions for removing and installing toothed belt. Refer to
Toothed belt, removing and installing .
- Install cylinder head cover. Refer to Cylinder head, removing and installing .
- Installing ribbed belt and tensioning element. Refer to Ribbed belt, removing and installing .
- 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.
- Then 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 adaption of throttle valve control module:
Refer to
- 24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AMU
- 24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): ATC
- 24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AWP
- 24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): BEA
- Interrogate DTC memory:
Refer to
- 01 ON BOARD DIAGNOSTIC (OBD) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AMU
- 01 ON BOARD DIAGNOSTIC (OBD) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): ATC
- 01 ON BOARD DIAGNOSTIC (OBD) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AWP
- 01 ON BOARD DIAGNOSTIC (OBD) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): BEA
NOTE:
DTCs will have been stored in the memory because connectors have been disconnected. Therefore interrogate and erase DTC memory after installing engine.
- Electrical connections and routing:
Refer to Electrical Wiring Diagrams, Troubleshooting & Component Locations