Start work only after the engine has completely cooled down!
Removing
All engines
1. Relieve the pressure in the supply system (see chapter Power and exhaust systems). Disconnect and remove the battery (see chapter Engine electrical equipment).
2. Empty the cooling system (see chapter Cooling, heating systems).
3. Remove the timing belt (see Removing and installing timing belt). Before loosening the timing belt, move the engine off TDC by turning the crankshaft 60°counterclockwise to equalize the distribution of forces developed by the valve springs and prevent the camshafts from turning, fraught with damage to the internal components of the mechanism as a result of the introduction of the pistons into contact with the valves.
Engines 1.4, 1.6 and 1.8 l
1. Remove the intake piping and exhaust manifold (see chapter Power and exhaust systems). If the cylinder head is not serviceable, it can be removed complete with pipeline and manifold:
2. Disconnect from a final collector a reception pipe of system of release of the fulfilled gases in gathering with a basic arm
3. Disconnect the electrical wiring from the lambda probe.
4. Disconnect the wiring from the crankshaft position sensor (CKP).
5. Remove the timing cover (see Removal and installation of a cover of the gas-distributing mechanism).
- Remove the camshaft gears (see Removal and installation of gear wheels crankshaft / camshafts and intermediate rollers).
- Turn out bolts of fastening of a back cover of a drive of GRM to the case of the timing mechanism.
- If you haven't done so already, disconnect the wiring harness from the control box (ECU) on the left side of the cylinder head.
- Release fastening collars and disconnect hoses of system of cooling from the case of the thermostat.
6. In order to remove the coolant from the cylinder block, disconnect the hoses from the heater heat exchanger to the inlet pipeline (see chapter Cooling, heating systems), — as soon as fluid flow stops, restore the original hose connection. Soak up spilled liquid with paper towels. Remove the two TORX head bolts and separate the hose connection flange from the rear of the cylinder head.
A - Removing the flange connecting the hose of the cooling system (engine 1.8 l)
B - Removing the flange connecting the cooling system hose (engines 1.4 and 1.6 l)
A.
B.
7. On 1.4 and 1.6L engines, release the two crankcase ventilation hoses from the ECU support bracket on the left side of the head.
8. On 1.8 liter engines, unscrew the mounting bolt and set aside the guide tube of the dipstick for measuring the level of impellent oil.
9. Make sure that all hoses, tubes, wires and other communication lines are disconnected and do not interfere with the dismantling of the cylinder head.
10. Acting in the reverse order shown, gradually, a quarter of a turn per approach, evenly loosen the cylinder head bolts so that they can be turned out manually. Remove the head bolts complete with your washers.
11. Lifting up, separate the cylinder head from the block - if necessary, tap it from the sides with a soft-faced hammer.
In no case do not pry the head with a lever in order to avoid damage to the mating surfaces! Mark the position of the two guide bushings, remove them from the block and put them in a safe place.
12. Remove the gasket—do not discard the gasket yet to identify a new one.
Engines 2.0 l
1. Remove the intake piping and exhaust manifold (see chapter Power and exhaust systems). If the cylinder head is not serviceable, it can be removed complete with piping and manifold.
2. Remove the timing cover (see Removal and installation of a cover of the gas-distributing mechanism).
3. Remove the camshaft gears (see Removal and installation of gear wheels crankshaft / camshafts and intermediate rollers).
4. Turn out bolts of fastening of a back cover of a drive of GRM to the case of the timing mechanism.
5. If the intake piping will not be removed, remove the generator/pipe support brackets and move the generator back.
6. Disconnect the accelerator cable (see chapter Power and exhaust systems).
7. Disconnect the brake booster servo vacuum hose from the inlet pipeline.
8. Disconnect the fuel lines from the fuel line.
9. Loosen the mounting clamps and disconnect the hoses of the cooling path from the heat exchanger of the heater and the throttle body.
10. If you have not already done so, disconnect the fuel injection injector wiring harness and move it aside.
11. Remove the exhaust camshaft (see Removal and installation of camshafts and valve lifters, checking the condition of components).
12. Make sure that all hoses, tubes, wires and other communication lines are disconnected and do not interfere with the dismantling of the cylinder head.
13. Proceeding in the reverse order shown, gradually, one third of a turn per approach, using a 12-point TORX T55 wrench (KM-2355) Loosen the cylinder head bolts evenly enough to allow them to be removed by hand. Remove the head bolts complete with your washers.
14. Lifting up, separate the cylinder head from the block - if necessary, tap it from the sides with a soft-faced hammer.
In no case do not pry the head with a lever in order to avoid damage to the mating surfaces! Mark the position of the two guide bushings, remove them from the block and put them in a safe place.
15. Remove the gasket—do not discard the gasket yet to identify a new one.
Preparing for installation
See Removal and installation of a head of cylinders.
Installation
All engines
1. Make sure the crankshaft is still turned at 60°before TDC.
2. Wipe dry the mating surfaces of the block and head with a clean rag.
3. Make sure both guide bushings are in place.
4. Lay a new sealing gasket on the mating surface of the cylinder block, - the gasket is placed with the marking «OBEN/TOP» up.
5. Install the head on the cylinder block - make sure that the guide bushings fit into the receiving sockets.
6. Place washers on the NEW cylinder head bolts, then carefully install the bolts and finger-tight.
7. Acting in a strictly defined sequence, in several stages evenly, tighten the bolts with the force of the 1st stage.
8. In the same order, tighten the bolts to the corners, first the 2nd, then the 3rd, 4th stages and the 5th, use the goniometer nozzle, or apply reference marks with paint or a marker.
Engines 1.4, 1.6 and 1.8 l
1. Restore the original coolant path hose connection - be sure to replace the flanged o-ring on the back of the head. Track reliability of a tightening of fixing bolts / collars.
2. Restore the original wiring connection. Follow the correct laying of the harnesses and the reliability of fixing them with all the provided clamps.
3. Establish a back cover of a gas-distributing belt, screw fixing bolts and tighten them with the demanded effort.
4. Install the camshaft gears (see Removal and installation of gear wheels crankshaft / camshafts and intermediate rollers).
5. Bring the engine to TDC (see Bringing the piston of the first cylinder to the position of the top dead center of the compression stroke (TDC)) and install the timing belt (see Removing and installing timing belt).
6. Install the timing and timing covers (see Removal and installation of a cover of the gas-distributing mechanism and Removing and installing timing cover).
7. Reinstall intake manifold and exhaust manifold (see chapter Power and exhaust systems).
8. Install the wheel, lower the vehicle to the ground and tighten the wheel bolts to the correct torque.
9. Check up correctness of laying and connection of hoses of a cooling path.
10. Make sure all hoses are routed and connected securely, then charge the cooling system (see chapter Cooling, heating systems).
11. Reinstall the ignition module, engine guard, and air cleaner assembly with air ducts.
12. Connect the battery.
13. Start the engine and check it for signs of developing fluid leaks.
Engines 2.0 l
1. Install the exhaust camshaft (see Removal and installation of camshafts and valve lifters, checking the condition of components).
2. Restore the original connection of the cooling path hoses.
3. Establish a back cover of a gas-distributing belt, screw fixing bolts and tighten them with the demanded effort.
4. Install the camshaft gears (see Removal and installation of gear wheels crankshaft / camshafts and intermediate rollers).
5. Follow the procedures from paragraph Engines 1.4, 1.6 and 1.8 l - item 5.
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