Tightening the cylinder head bolts to the required torque
Tightening the cylinder block mounting bolts by turning them to a certain angle
Removing
Warning! The cylinder head must be removed when the engine is cold. When installing the head, it is necessary to use new head bolts.
1. Depressurize the fuel system. Remove the ground wire from the battery.
2. Drain the coolant from the cooling system and remove the spark plugs.
3. Remove the toothed belt. Rotate the engine crankshaft back approximately 60°before removing the toothed belt (4 teeth), which will allow you to install the camshafts so that the pressure of the valve spring is even along the entire length of the camshaft.
1.6L engines
4. Remove the intake and exhaust manifold. If the cylinder head will not be disassembled, it can be removed together with the manifolds after performing the following steps:
- disconnect the exhaust pipe from the exhaust manifold;
- disconnect the electrical connector from the oxygen sensor;
- Disconnect the air tube and vacuum hose from the air injector valve.
5. Remove the camshaft covers.
6. Remove the camshaft pulleys and idler toothed belt pulleys.
7. Unscrew bolts of fastening of a back casing of a gear belt to a head of the block of cylinders.
8. Remove the power steering pump bolt and move it away from the head.
9. Disconnect the electrical connectors from the DIS block and the coolant temperature sensor on the cylinder head.
10. Loosen the clamps and disconnect the upper coolant hose connecting the cylinder head and radiator. Loosen the clamp and disconnect the coolant hose connecting the cylinder head and expansion tank.
11. Disconnect the coolant supply hoses to the heater from the bulkhead of the engine compartment in order to drain the coolant from the cylinder block. After draining the coolant, reconnect both hoses to the heater.
12. Working in sequence, loosen the cylinder head bolts 1/3 turn each pass until the bolts are completely loose (see fig. Cylinder head bolt tightening sequence).
13. Remove the cylinder head from the cylinder block.
14. Remove the cylinder head gasket.
Engines 1.8 and 2.0 l
15. Remove the intake and exhaust manifolds. If the cylinder head will not be disassembled, it can be removed together with the manifolds after disconnecting all hoses and electrical wires.
16. Remove the cylinder head cover.
17. Remove pulleys from camshafts.
18. Unscrew the torque compensator rod mounting bolt from the end face of the cylinder head.
19. Unscrew bolts of fastening of a back casing of a gear belt to a head of the block of cylinders.
20. Loosen the clamps and disconnect the upper coolant hose connecting the cylinder head and radiator. Loosen the clamp and disconnect the coolant hose connecting the cylinder head and expansion tank.
21. Disconnect the coolant supply hoses to the heater from the bulkhead of the engine compartment in order to drain the coolant from the cylinder block. After draining the coolant, reconnect both hoses to the heater.
22. Working in sequence (see fig. Cylinder head bolt tightening sequence), loosen the cylinder head bolts 1/3 turn each pass until the bolts are completely loose.
23. Remove the cylinder head from the cylinder block.
24. Remove the cylinder head gasket.
Preparing the head for installation
1. The mating surfaces of the head and cylinder block must be perfectly clean. Use a hard plastic or wooden scraper to clean them. Be careful when cleaning as aluminum alloy is very easy to damage. Check that carbon deposits do not get into the oil and water channels. This is especially important for the lubrication system, as deposits can block the oil supply to engine components. If necessary, clean the channels, check the mating surfaces of the head and cylinder block for nicks, deep scratches and other damage. If the defects are small, they can be removed by machining. But in case of significant defects, the parts must be replaced.
2. Using a metal ruler and feeler gauge, check the flatness of the mating surfaces.
3. Clean the bolt holes in the block. Screwing a bolt into an oil-filled hole can rupture the block due to hydraulic pressure.
Installation
1. Check that the crankshaft is set 60°back from top dead center on the #1 piston. Wipe mating surfaces of the head and cylinder block.
2. Check that the new cylinder head gasket is the same type as the original and that the TOP or OPEN·markings are facing up.
3. Install the cylinder head on the guide pins.
4. Install new cylinder head bolts and hand tighten at this stage.
5. Gradually and consistently (see fig. Cylinder head bolt tightening sequence) Tighten all cylinder head bolts to the required torque in several stages.
1.6L engine
6. Connect the cooling system hoses and secure with clamps.
7. Connect electric sockets to a head of the block of cylinders.
8. Install the power steering pump.
9. Establish a back casing of a gear belt, fasten bolts, having tightened them the demanded moment.
10. Install pulleys on camshafts and idler pulleys.
11. Align all the pulley alignment marks with the pointers and install the toothed belt.
12. Install the cylinder head cover and toothed belt guard.
13. Install intake and exhaust manifolds.
14. Install the wheel and lower the car.
15. Check that all pipes and hoses are securely connected and add coolant to the cooling system and screw in the spark plugs.
16. Connect the battery, start the engine and check for leaks.
Engines 1.8 and 2.0 l
17. Connect the cooling system hoses and secure with clamps.
18. Install the rear toothed belt cover and secure with bolts, tightening them to the required torque.
19. Connect the torque compensator rod to the cylinder head and tighten the mounting bolt to the required torque.
20. Install the camshaft pulleys.
21. Align all the pulley alignment marks with the pointers and install the toothed belt.
22. Install the cylinder head cover and toothed belt guard.
23. Install intake and exhaust manifolds.
24. Install the wheel and lower the car.
25. Check that all pipes and hoses are securely connected and add coolant to the cooling system and screw in the spark plugs.
26. Connect the battery, start the engine and check for leaks.
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