You will need: torque wrench, keys «at 13», «at 17», «at 19», end heads «on 10», «at 13», «at 17», «Togh», screwdriver.
Warning! The head gasket is single use, so the gasket must be replaced each time the head is removed.
1. Disconnect the wire from the terminal «-» battery.
2. Set the piston of the 1st cylinder to the TDC position of the compression stroke (see «Setting the piston of the first cylinder to the TDC position of the compression stroke»).
3. Drain the coolant (see «Coolant replacement»).
4. Reduce the pressure in the power system if work is performed immediately after a trip (see «Reducing the pressure in the power system».
5. Disconnect the muffler downpipe from the exhaust manifold (see «Downpipe replacement».
6. Remove the cylinder head cover (see «Replacing the Head Cover Gasket»).
7. Disconnect the wiring harness block from the mass air flow sensor, loosen the clamp securing the air inlet pipe to the throttle assembly and remove the pipe with the air filter housing and air intake hose from the throttle assembly (see «Removal and installation of the air filter»).
8. Turn away a nut 1 fastenings of an arm of an inlet pipe of the water pump. Loosen the nut 2 securing the inlet pipe bracket to the exhaust manifold.
9. Move the bracket aside.
10. Loosen the clamps.
11.... and disconnect the inlet and outlet hoses of the cooling system from the throttle assembly.
12. Loosen the hose clamp of the vacuum brake booster hose to the fitting on the receiver..
13.... and remove the hose.
14. Turn the throttle actuator sector to the stop and disconnect the throttle actuator rod from it.
15. Turn off two nuts of fastening of tips «massive» wires to the back cover of the head of the block..
16.... and remove the wires from the studs.
17. Turn away a nut of the lower fastening of a strut 1 and turn out a bolt of the lower fastening of a strut 2…
18.... unscrew the nuts of the upper fastenings of the intake manifold spacers on the right..
19.... and on the left side, remove the spacers.
20, Disconnect the wiring harness pads from the oil level sensors in the crankcase..
21.... from the throttle position sensor..
22.... from the idle speed controller..
23.... from the injector wiring harness..
24.... from the coolant temperature sensor..
25.... from the crankshaft position sensor and knock sensor.
26. Disconnect the wire blocks from the coolant temperature indicator sensor..
27.... and from the oil pressure sensor.
28. Disconnect tips of high-voltage wires from spark plugs.
29. Pull the wiring harness out from under the receiver.
30. Remove the three screws securing the front cover of the camshaft drive belt, remove the cover..
31....and a belt (see «Replacing the camshaft drive belt and adjusting the belt tension»).
Warning! It is forbidden to turn the crankshaft and camshaft before installing the camshaft timing belt.
32. Fix the camshaft pulley from turning, unscrew the bolt securing the pulley to the camshaft..
33.... and remove the bolt along with the washer.
34. Remove the pulley from the camshaft. Do not damage the camshaft seal.
Note. If the key is loose in the camshaft nose groove, remove it so as not to lose it.
35. Turn away a nut of fastening of a back cover of a drive of a camshaft in the top part of a head of the block.
36. Turn out four bolts (three of them also fixed a water pump) and remove the back cover (see «Engine repair (disassembly, Troubleshooting, assembly)»).
37. Remove the fastening nut «mass» wires..
38.... and remove the wire from the stud securing the cooling system exhaust pipe to the cylinder head.
39. Loosen the clamps and remove the inlet pipe of the radiator 2, the inlet hoses of the throttle assembly 4 and heater 3 from the outlet pipe, disconnect thermostat 5 together with hose 1.
40. Turn away nuts of fastening and disconnect hoses of giving and discharge of fuel from fuel tubes, keeping hoses from turning by the second key.
41. Pay attention to the fact that o-rings are installed on the fuel pipes.
After disconnecting each hose, remove the O-ring from the tube. Replace heavily compressed or torn rings.
42. Loosen the ten bolts of the head of the block in the specified order, then finally unscrew the bolts of the head, remove them together with the washers and remove the head.
Note. It is necessary to unscrew the bolts of the cylinder head with a special socket «Togh».
Warning! Do not drive a screwdriver or other tools between the head and cylinder block.
Helpful advice. To pry the head off the gasket, insert a screwdriver under the exhaust manifold. Using it as a lever, lift the head.
43. Remove the head gasket.
Note. Cylinder head bolts stretch out with repeated use. Replace with new bolts that are longer than 135.5 mm. Before installing the block head, lubricate the bolts with a thin layer of engine oil.
44. Clean the mating surfaces (they must be dry and clean) head and cylinder block and remove oil from the threaded holes in the block for the head bolts.
45. Install a new head gasket on the block (gasket must be dry and clean) along the mounting sleeves so that the oil passage hole in the gasket (with copper trim) was between the 3rd and 4th cylinders.
46. Install the head on the block, after making sure that the crankshaft and camshafts are in the TDC position (both valves of the 1st cylinder must be closed). Tighten the head bolts in the following sequence in four steps:
1 - torque 20 N.m (2 kgf-m);
2 - torque 69.4-85.7 Nm (7.1-8.7 kgf-m);
3 - tighten the bolts by 90°;
4 - finally tighten the bolts by 90°.
47. Install the parts on the head of the block and connect the hoses and wires to it in the reverse order of removal. Install the camshaft pulley with the protruding part of the hub towards the engine.
Check and, if necessary, adjust the clearances in the valve drive (see «Valve clearance adjustment»). Adjust the tension of the camshaft drive belt (see «Replacing the camshaft drive belt and belt tension adjustment»).