A leak may also occur as a result of warping of the cylinder head due to overheating.
You will need: the same tools as for removing the timing belt (see Replacing the timing belt), camshafts of the gas distribution mechanism (see Removal, inspection and installation of camshafts) and cylinder head covers (see Replacing the cylinder head cover gasket).
1. Reduce the pressure in the fuel system (see Reducing pressure in the fuel system).
2. Disconnect the wire from the negative terminal of the battery.
3. Drain the cooling system (see Replacing the coolant).
4. Remove the timing belt from the camshaft pulleys (see Replacing the timing belt).
5. Remove the air filter and air duct (see Removal and installation the air filter, air duct and intake noise muffler).
6. Press the lock…
7. …and disconnect the wiring harness connector from the electro-hydraulic valve of the exhaust camshaft.
8. In a similar manner, disconnect the wiring harness connector from the electro-hydraulic valve of the intake camshaft.
9. Press the lock…
10. …and disconnect the wiring harness connector from the coolant temperature sensor.
11. Loosen the engine wiring harness bracket mounting nut…
12. …remove the bracket from the stud and move the wiring harness to the side.
13. Disconnect the wiring harness connector from the intake camshaft position sensor.
14. Similarly, disconnect the wiring harness connector from the exhaust camshaft position sensor.
15. Disconnect the wiring harness connectors from the fuel injectors.
16. Unscrew the bolt securing the negative wire tip to the cylinder head and move the wire to the side.
17. Press the lock and disconnect the wiring harness connector from the coolant temperature sensor.
18. Loosen the clamp securing the coolant outlet hose from the branch pipe by squeezing its bent tabs with pliers. Slide the clamp along the hose…
19. …and disconnect the hose from the branch pipe.
20. Similarly, loosen the clamp securing the hose to the thermostat pipe..
21. …and disconnect the hose from the branch pipe.
22. Press the lock and disconnect the vacuum hose from the inlet pipe (receiver).
23. Remove the catalytic converter (see Removal and installation the catalytic converter, replacing its gasket).
24. Loosen the clamp securing the coolant outlet hose from the branch pipe by squeezing its bent tabs with pliers. Slide the clamp along the hose…
25. …and disconnect the hose.
26. Remove the camshafts (see Removal, inspection and installation of camshafts).
27. Remove the two bolts securing the water distribution pipe to the water pump…
28. …bolt for fastening the water distribution pipe to the cylinder block…
29. …two screws securing the pipe to the thermostat module…
Note: One of the screws that secures the pipe to the thermostat module is not visible in the photo because it is covered by the pipe.
30. …and remove the water distribution pipe.
Caution! The flanges of the water distribution pipe are sealed with a rubber ring. Replace the ring each time the connection is disassembled.
31. Slide the heat shield along the wire harness…
32. …move the wiring harness connector retainer to the side…
33. …and disconnect the wiring harness connector from the oil pressure sensor.
34. Disconnect the plastic holders of the engine wiring harness from the engine brackets by cutting them with pliers, and remove the wiring harness from the engine compartment.
35. Loosen the ten bolts securing the cylinder head to the cylinder block in the sequence shown in Fig. 1.
Fig. 1. The order of unscrewing the cylinder head mounting bolts
Attention! The cylinder head mounting bolts can only be removed when the engine is cold.
36. Remove the cylinder head assembly with the engine intake pipe…
37. …and remove its gasket.
Note: Remove the cylinder head with an assistant, as it is quite heavy.
38. Clean the mating surfaces of the head and block.
39. Check the cylinder head for warping. To do this, place a ruler on its edge on the surface of the head, first in the middle along, then across and diagonally, and measure the gap between the surface of the head and the ruler with a feeler gauge. Grind the cylinder head if the gap is more than 0.1 mm.
40. Install the cylinder head in the reverse order of removal, taking into account the following:
- remove any oil and coolant from the threaded holes of the cylinder head mounting bolts that got there when the head was removed;
- be sure to install a new cylinder head gasket, it cannot be reused;
- lubricate the bolts with engine oil;
- tighten the bolts on a cold engine in the order shown in Fig. 2, to the specified torque.
Fig. 2. The order of screwing in the cylinder head mounting bolts
41. Install the camshafts in the sequence specified in subsection Removal, inspection and installation of camshafts.
42. Install all previously removed parts in the reverse order of removal.
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