Removing
Disconnect the wire from the negative battery terminal.
Remove the mass air flow meter with mounting bracket and the air hose connecting the meter to the air filter.
Remove the air supply hose to the air filter and the air filter. Remove the plug from the expansion tank, disconnect the outlet hose from the radiator and drain the coolant into a container.
Disconnect the throttle cable. Disconnect the cables and hoses from the head.
Remove exhaust manifold.
Remove the camshaft drive belt as shown below.
Remove the protective cover of the spark plugs and disconnect the wires from the spark plugs.
Remove cylinder head cover.
Unscrew the bolts securing the camshaft pulleys, holding the shafts with a wrench by the hexagon made on them, and remove the pulleys.
Remove the toothed belt tensioner, remove the idler roller and tapered roller spacers.
Remove rear toothed belt cover.
After the engine has cooled down to a temperature not exceeding 60°C (the temperature maintained by the hand when touched) loosen ¼ turn all head bolts in order. shown in the figure, then unscrew them another ½ turn. Loosen the bolts completely and remove the steel washers.
Remove the head from the cylinder block. separating it first at the points located on the 1st and 4th cylinders from the side of the exhaust camshaft.
Remove the cylinder head gasket.
Installation
Clean the mating surfaces of the cylinder head with (e.g. Decaploc 82). Never use cutting or abrasive tools to clean the surface of aluminum parts
Install the cylinder head gasket without sealant «Oben-tor» («Top») up, orienting it towards the camshaft drive.
Install the cylinder head.
Tighten the ten head mounting bolts with washers, after lubricating the threads of the bolts and the rod under the head with engine oil. Do not grease washers. Screw all the bolts evenly in the order shown in the figure until resistance appears using a socket with a hexagon socket wrench MKM 604-18, tighten the bolts in order in several steps (see subsection «Design and specifications»).
Install the rear cover of the toothed belt and tighten the bolts of its fastening to a torque of 0.6 kgf·m, having previously lubricated the threads of the bolts with a locking compound.
Install the tensioner and support rollers of the toothed belt
Install the camshaft pulleys so that the marks on the pulleys and the drive pins on the shaft flanges point upwards (see picture).
Holding the camshafts with a wrench by the hexagon, tighten the bolts securing the pulleys to a torque of 5.0 kgf·m, followed by a further turn of 60-75°.
Install the cylinder head cover with a new gasket and tighten the mounting bolts to a torque of 0.8 kgf·m.
Connect both crankcase ventilation hoses.
Connect the wires to the spark plugs, replace the protective cover of the spark plugs.
Install the exhaust manifold.
Slide the toothed belt over the pulleys and adjust its tension as shown below.
In the future, the installation of the cylinder head is carried out in order. reverse withdrawal.
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