Contents: Removal ↓ Installation ↓
We remove the cylinder head without disconnecting the receiver, intake manifold and exhaust manifold.
To complete the work you will need a torque wrench.
Removal
1. Place the vehicle on an inspection pit or overpass (see "Preparing a car for maintenance and repair").
2. For ease of work, remove the battery (see "Battery - Removal and Installation").
3. Drain the coolant (see "Coolant - Checking Level and Replacing").
4. Disconnect the wire tip from the coolant temperature gauge sensor (see "Coolant Temperature Gauge Sensor - Replacement").
5. Unscrew the spark plugs from the cylinder head (see "Spark plugs - checking condition and replacement").
6. Remove the intake pipe from the exhaust manifold studs (see "Intake pipe - removal and installation").
7. Set the piston of the 4th cylinder to the BMT position of the compression stroke and remove the housing assembly with the camshaft, valve drive levers and springs (see "Camshaft and valve levers - replacement").
8. Tie the chain with wire and pass it through the window in the cylinder head.
9. Unscrew the nut of the upper fastening of the starter heat shield (see "Starter - removal and installation")
10. Remove the ground wire tip from the exhaust manifold stud (see "Intake manifold and exhaust manifold gasket for injection engine - replacement").
11. Disconnect the wire connectors from the throttle position sensor (see "Throttle Position Sensor - Checking and Replacing") and the coolant temperature sensor (see "Coolant Temperature Sensor - Checking and Replacing").
12. Disconnect the wiring harness from the idle speed control valve (see "Idle speed control valve - checking, removal and installation") and the injector wiring harness block from the engine harness (see "Fuel rail - removal, installation and testing of injectors").
13. Remove the throttle cable from the housing sector (see "Throttle body - removal and installation") and, having unscrewed the two bracket mounting bolts, move the bracket with the cable to the side (see "Receiver - removal and installation").
14. After loosening the clamps, remove the thermostat bypass hose and the radiator supply hose.
15. After loosening the clamp, remove the hose supplying coolant to the heater radiator from the branch pipe.
16. Disconnect the coolant drain hose and air duct from the throttle body pipes (see "Throttle body - removal and installation").
17. Disconnect the brake booster hose from the receiver pipe (see "Receiver - removal and installation").
18. Disconnect the fuel supply and drain hoses from the ramp tubes (see "Fuel rail - removal, installation and testing of injectors").
19. With a socket wrench by 12 mm using an extension, unscrew the ten bolts that secure the internal mounting of the head to the cylinder block.
20. With a socket wrench by 13 mm we unscrew the bolt of the outer fastening of the head to the cylinder block.
21. Remove the cylinder head assembly with the intake manifold and exhaust manifold.
22. Remove the gasket from the two centering bushings of the cylinder block.
Installation
1. Install the new gasket and cylinder head in the reverse order, passing the wire with the chain through their windows.
2. Before installing the cylinder head, it is necessary to lubricate its mounting bolts with engine oil in advance and allow excess oil to drain, holding the bolts for at least 30 minutes.
Attention! Cylinder head mounting bolts may only be reused if they have stretched to a length of no more than 115.5 mm. If the length is greater, the bolt must be replaced.
3. Tighten the cylinder head mounting bolts in four steps:
- pre-tighten ten internal head mounting bolts to 20 Nm;
- we tighten them with a torque of 69.4-85.7 Nm.
- we turn the bolts by 90°;
- we turn the bolts again by 90°.
Finally, tighten the outer mounting bolt (11) to a torque of 30.6-39.1 N·m.
Cylinder head bolt tightening sequence
4. Install the housing with the camshaft on the cylinder head studs and tighten the mounting nuts (see "Camshaft and valve levers - replacement").
5. Untie the wire, install the sprocket with the chain on the camshaft, tighten the mounting bolt and lock it by bending the tab of the lock washer.
6. "Charge" the chain tensioner and, having installed it in its original place, "discharge" it (see "Timing Chain Tensioner - Replacement") and adjust the chain tension (see "Timing Chain - Tension Adjustment").
7. Adjust the clearance between the levers and the camshaft cams (see "Clearance between valve levers and camshaft cams - adjustment").
8. Installation of removed parts is performed in reverse order.
9. Fill the system with coolant (see "Coolant - Checking Level and Replacing").