Install the cylinder head cylinder Lindrum 4A-GE (AE92, a number 11 and AT160)

Install the cylinder head cylinder ¬ Lindrum 4A-GE (AE92, a number 11 and AT160)
1. Set the choke.
a) Apply adhesive to 2-3 last round of the thread.
Glue: SHST1TE242 or equivalent.
b) Tighten the connection (MH = 29 Nm).
2. Set shipping hooks (eyebolts) engine, fixing their 2 - ring bolts with the "grounding" conductor (MZ = 25 Nm).
3. Install the cylinder head cylinder ditch.
Note:
• Bolts cylinder head tightened gradually for 3 passes.
• If a bolt is broken or deformed, replaceit.
a) Place the new cylinder head gasket, given the position ¬ tion guides on the block.
b) Place the gasket on the cylinder head.
Note: Before installing Nana ¬ sieve a small layer of engine oil to bolt threads and under the head-ki bolts.
9 5 2 4 "
e) Tighten all bolts in the marked-tion above the sequence in ¬ returning them to 90 °.
c) with a suitable adapted ¬ sobleniya install and tighten gradually in several passes (at least 3) 10 bolts of ¬ deft block in the sequence shown in the figure (final ¬ ny MZ = 29 Nm).
If you do not reach the bolts ¬ Xia required time, replace the bolt. Please note:
• head bolts are of different lengths of 90 mm (screws A) and 108 mm (bolt in).
• Bolts A (length 90 mm) shall establish at the head of the intake manifold (right side when viewed from the hand ¬ HN PTO).
• Bolts in (108 mm in length) ustanav ¬ Lebanon at the head of the exhaust manifold (left side when viewed from the hand ¬ HN PTO).
g) Mark the edge of the bolt is turned to ¬ nuyu front of the engine (the side opposite the power take-off) paint, as shown in the figure.
g) Ensure that all tags bolts oriented 180 ° from the initial position of ¬ and face the rear of the engine (to the PTO). 4. Set the hose system when number 2 ¬ nuditelnoy crankcase ventilation, per ¬ attaches it with 2 clamps (clamps).
5. Install the distribution wa ¬ ly and bearing caps inflammatory dis ¬ shafts.
a) Install the camshafts in the cylinder head bore a cylinder chi ¬, ¬ nye ustanovoch oriented pins, as shown in the figure.
Note: The camshaft exhaust valve has a gear drive ignition distributor. b) Apply sealant to the areas of agile-cylinder, as shown in the figure. Sealant: RAP № 08826-00080 or equivalent
7. Set the right support engines ¬ la, securing the support (№ 1) - three ball ¬ Tami, and support (№ 2) - two bolts. Tightening torque:
Reliance № 1 39 Nm
d) Apply a small layer of motor oil is in ¬ thread bolts and head bolts for bearing caps camshafts.
d) Install and uniformly tighten ¬ are a few passages bearing caps bolts in the sequence ¬ sequence, shown in Figure (MH = 13 Nm).
• Reliance number 2 21 Nm
Note: 4A-OE models AE92, AT160 and ASH11 release before 1987 installed a right-bearing, is secured by three bolts (MZ = 25 Nm).
8. Install the toothed pulleys leads ¬ da camshafts (see "timing belt"). Tightening torque of fixing screws:
AE92, AT160 and ASH11
produced before 1987 47 Nm
For the rest of AE92. . . . 59 Nm
g) with a suitable adapted ¬ sobleniya install seals distribution Note: Be careful
do not allow the change (bias) mesh gear timing belt with a toothed pulley of a cranked shaft of ¬.
10. Check the installation phase gazoras ¬ tribution and the belt tension at the water ¬ timing.
a) Slowly release the bolt ¬ gained strength of tension pulley timing belt.
9. Install the timing belt under ¬ water timing, pre-aligning the pulleys on a tag to zubcha ¬ is the timing belt as shown.
Please note:
• Stuffing box must be installed as shown.
• Stuffing box is set to point races ¬ head unit until it stops.
a) Install the bearing caps on the corresponding camshaft ¬ sponding places.
6. Replace the cover № 4 timing belt, tightening the screws 7 (MH = 9.3 Nm).



c) Make sure that: '
• Adjusting the label on each pulley coincide with the relevant labels gazoras phase-distribution on the cover № 4 timing belt, as shown in the figure;
• mounting mark (notch) crankshaft pulley (pulley generator and pump fluid lazhdayuschey ¬ oh) coincides with the zero mark of the scale, as shown by ¬ in the figure.
Note: If the label on the pulleys do not coincide with their response labels, change the (slide) for tseplenie-sprocket-kolencha of the shaft with a toothed belt actuators ¬ da timing and re-regulation repeat ¬ focusing, as described in claim 8, 9 and 10.
d) Tighten the set screw on ¬ tyazhnogo pulley (roller) of the belt under ¬ water timing (MH = 37 Nm).
d) Check the belt tension at the water ¬ timing, checking its deformation ¬ tion by applying a normalized amplification ¬ Leah at the point shown.
Belt deflection of 4 mm under a force 20 N.
If the measured value does not correspond ¬ corresponds to technical conditions, lead ¬ tension adjustments are changing the on ¬ Proposition tensioner pulley (roller) timing belt.
1 1. Install the spark plugs (MZ = 18 Nm).
12. Install the cylinder head cover. a) Apply sealant to the areas of agile ¬ cylinder, as shown in the figure. Sealant: RAP number 08 826 - 00 080 or equivalent.
b) Place the gasket on the end caps of the cylinder head.
a) Install the two side covers of nimble-cylinder, fixing them with 4 cap nut, ¬ mouth with defined through the sealing washers.
Tightening torque: AE92, AT160 and ASH11
produced before 1987 13 Nm
For the rest of AE92. 7.8 Nm
g) Install the gasket on the cen-tral head cover of the cylinder.
d) Attach the center cap
6 - u bolts.
13. Install protective cover number 2 and number 3 the timing belt. -
a) Install the gasket under the lid .-
b) Place the lid, securing them together with a bracket for high volt ¬ wires and secure them
7 - u bolts.
Note: The length of the mounting ball ¬ Comrade and place of installation indicated in the figure.
14. Install the pump pulley ¬ cooled liquid and giving the belt alternator and water pump.
15. Set up supply of cooling fluid which gives ¬ (see "Cooling System").
16. Set the node (block) nozzle discharge and bypass the coolant with a new gasket, securing it with 3 bolts.
Tightening torque of bolts from the outside:
Cylinder head 27 Nm
Intake manifold 13 Nm
Then the tension bar generator and attach it with 3 bolts (MZ = 18 Nm).
17. Install the intake manifold. (For the serial version of the 4A-DE) a) Install the intake manifold with new gasket, fixing his 7 bolts and 2 nuts (MZ = 27 Nm).
b) Install the support rack inlet ¬ Nogo collector and attach it with 2 screws.
Tightening torque of bolts:
Turnkey 14 mm. 39 Nm
Turnkey 12 mm. 22 Nm
(For 4A-DE with a variable geometry intake system ¬ s) a) Place: a new gasket, pro-rate additional dampers. gasket and intake manifold, for ¬ fastens them together 7th bolts and 2 nuts (MH = 27 N m).
b) Place the hose at ¬ nuditelnoy crankcase ventilation.
a) Install the rack supporting the WLS-sknogo collector, securing it with 2 nuts (MH = 22 Nm).
18. (For 4A-0E variable-geometry intake system) Install Electro-switch ("switch resolution ¬ zheniya") management system geometry ¬ riey intake manifold assembly with a vacuum chamber, fixing them with 2 bolts. Then connect the vacuum hoses ¬ nye.
19. Install the throttle body (see "Fuel Injection System).
20. Install the rear (butt), cylinder head cover and a vacuum tube (the last - only in the presence of EGR).
(Engine system without recirculation of exhaust gases ¬ tion)
a) Install (with a new gasket)
, The rear head cover and fasten it over ¬ with 2 bolts.
b) Connect the following connectors:
• timer nozzle ¬ Nogo cold engine start
• temperature sensor cooling ¬ giving liquid.
(Engine with EGR) a) Set (with a new gasket) rear head cover and the vacuum tube ¬ smart, fixing them with 4 ball ¬ Tami.
b) Connect the vacuum hoses.
a) Connect the following connectors:
• timer nozzle ¬ Nogo cold engine start;
• temperature sensor cooling giving fluids;
• electro-pneumatic valve system for recycling ¬ ¬ otrabo tavshih gases.
21. Attach the wiring motion ¬ gatelya the intake manifold with 2 bolts and connect the following ports:
• electro-pneumatic valve differential pressure top ¬ Lebanon (only for European models of mo ¬);
• cold start injector motion gatelya ¬;
• throttle position sensor for ¬ slonki;
• knock sensor.
22. Install the nozzle and then the general ¬ plivoprovod (collector) jets (see "Fuel Injection System").
23. Install injector cold start the engine (see "System vpry fuel-ska").
24. Set the hose forced labor ¬ convincingly crankcase ventilation.
25. Install the exhaust manifold. a) Install the lower screen (insulator) of the exhaust manifold, securing it with 3 bolts.
a) Install the right and left pillars ¬ nye rack exhaust manifold, fixing them with 2 bolts and 2 nuts (on some models - 3 - ring bolts and nuts), MH = 39 Nm.
(AE GOLKO I AN
NOTE: Engine model ASH11 installed only right-hand support column is secured to a bolt and nut.
g) Install the upper screen (insulator) of the exhaust manifold, securing his 6-bolts.
26. (Engine with retsirku-modulation of exhaust gases) Install the valve system retsirku ¬ modulation of exhaust gases and trans ¬ zovatel (modulator) dilution, a) Set (with a new gasket) recycling valve assembly with tubing, fixing unit 4-ball ¬ Tami . Tightening torque: bleed screw
(Bolt-fitting) 69 Nm
mounting bolts 19 Nm
b) Set the transmitter (modulator) dilution, the mounting bolts.
a) Install the vacuum hoses.
27. Install the distributor ignition system ¬ topic (see chapter "Ignition system").
28. Connect the wiring to the motor protective cover № 4 timing belt and plug connectors:
• alarm sensor pressure drop of oil;
• electrical distributor.
29. Fill cooling system with coolant (see "Cooling System").
30. Start the engine and check for leaks.