Installing the cylinder head of the K4M engine

We fit the cylinder head after repair, inspection and fault assessment.

Before fitting the cylinder head, we set the cylinder pistons to mid-stroke.

The mating surfaces of the head and the cylinder block must be degreased.

We check that the guide bush is present on the cylinder block.

We fit onto the cylinder block the Mot.104 tool or a cut-down stud as a second guide.

We fit the cylinder head gasket onto the cylinder block.

We fit the cylinder head.

We unscrew the Mot.104 tool or the cut-down stud used as a second guide.

1. We tighten the cylinder head retaining bolts in the sequence shown in Figure 1 to a torque of 20±2 N·m.
2. After tightening the bolts, we additionally turn all the bolts in the indicated sequence through an angle of 240±6°.

We fit the valve hydraulic compensators (Fig. 2).

We check the serviceability of the hydraulic tappets: we press on the upper part of the hydraulic tappet; if the cylinder is pressed in easily, the hydraulic tappet may be clogged with resins. The hydraulic tappet must be immersed in kerosene or diesel fuel to dissolve the resins. After that, the hydraulic tappet must be immersed in oil and checked again. If after this the hydraulic compensator does not become elastic, the hydraulic compensator is faulty and must be replaced.

We fit the valve rockers (Fig. 3).

We lubricate the camshaft bearings with engine oil.

We fit the camshafts Removal of the K4M camshafts and hydraulic compensators.

Degrease the mating surface of the head and the cylinder head cover.

Using a roller, we apply Loctite 518 sealant until it turns reddish. If sealant gets onto the camshaft bearings, we wipe it off without fail.

We fit the cylinder head cover.

We tighten the cylinder head cover in the sequence shown in Figure 6, in stages:

• stage 1 — bolts 22, 23, 20 and 13 to a torque of 8 N·m (0.8 kgf·m);
• stage 2 — bolts 1–12, 14–19, 21 and 24 to a torque of 15 N·m (1.5 kgf·m);
• stage 3 — slacken bolts 22, 23, 20 and 13;
• stage 4 — tighten bolts 22, 23, 20 and 13 to a torque of 15 N·m (1.5 kgf·m).

1. We unscrew the eccentric cam tappet retaining bolt (1) of the Mot.1669 tool (see Fig. 7).
2. We screw in the standard eccentric cam tappet retaining bolt (2), applying a drop of Loctite Frenetanch (adhesive sealant) to its thread.
3. We tighten the eccentric cam tappet retaining bolt to a torque of 15 N·m.

We apply Loctite 518 sealant to the mating surface of the oil separator cover (Figure 8).

We fit the oil separator cover.

In the indicated sequence, to the required torque, we tighten the new oil separator retaining bolts in the unthreaded holes and the new or existing oil separator cover retaining bolts in the threaded holes (see Fig. 9).

1. We fit the camshaft phaser solenoid valve oil seal with the Mot1513 tool (see Fig. 10) and the intake camshaft phaser solenoid valve.
2. We tighten the intake camshaft phaser solenoid valve retaining bolts to a torque of 10 N·m.

Using the tool (2) Mot1503, we fit the cylinder head cover plug (1) (Figure 11).

We apply GRAISSE FLUORE grease to all four ignition coils (strip width 2 mm) around the inner circumference of the high-tension lead cap (Figure 12).

We screw in the spark plugs. We fit the ignition coils in place.

We fit the camshaft sensor with a new gasket in place (Figure 13).

We fit the intake pipe gaskets and fit the intake pipe.

We tighten the intake pipe in accordance with Figure 14.

Further assembly is carried out in the reverse order of dismantling.

Tightening torques of the fasteners when fitting the cylinder head