Removing
Warning! Removal of a head of the block of cylinders make on the cold engine. For fastening of a head of the block of cylinders it is necessary to use new bolts.
1. Depressurize the fuel system and 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.
4. Remove the intake and exhaust manifolds. If disassembly of the cylinder head is not required, it can be removed together with the manifolds. But for this you need to do the following:
- disconnect the electrical connectors from the throttle body and manifold and release the wiring harness from the intake manifold;
- disconnect the fuel supply hoses from the throttle body and the coolant supply hoses to the intake manifold;
- unscrew the bolt from the intake manifold support suspension and the upper alternator mounting bolt;
- disconnect the accelerator cable;
- unscrew the front exhaust pipe from the exhaust manifold and disconnect the oxygen sensor.
5. Remove the cylinder head cover.
6. Remove the camshaft pulley.
7. Unscrew bolts of fastening of a back casing of a gear belt to the case of a camshaft.
8. Disconnect the electrical connectors from the DIS block and coolant temperature sensor.
9. Loosen the clamp and disconnect the coolant hose from the thermostat housing.
10. Check that all hoses, pipes and wires are disconnected from the cylinder head.
11. In the reverse order to tightening, gradually unscrew the cylinder head bolts.
12. Remove the camshaft housing from the cylinder head.
13. Remove the cylinder head from the cylinder block. At the same time, do not displace the pushers and thrust pads.
14. Remove the cylinder head gasket.
Preparing 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 have not entered the oil and water channels. This is especially important for the lubrication system, as deposits can block the oil supply to engine components. Clean channels if necessary.
2. Check the mating surfaces of the cylinder head and block for nicks, deep scratches or other damage. If the defects are small, they can be removed by machining. But in case of significant defects, the parts must be replaced.
3. Using a metal ruler and feeler gauge, check the flatness of the mating surfaces.
4. Clean the bolt holes in the block. Screwing a bolt into an oil-filled hole can rupture the block due to hydraulic pressure.
5. Replace the cylinder head bolts regardless of their condition.
Installation
1. Check that the piston of the first cylinder is at top dead center.
2. Check that the two guide rods are installed in the cylinder block.
3. Install a new cylinder head gasket. The arrows mark the position of the guide pins.
4. When installing, make sure that the TOP / OBEN·marking is directed upwards.
5. Install the cylinder head on the guide pins.
6. Check that the mating surfaces of the cylinder head and camshaft housing are clean and dry. Check that the alignment mark on the camshaft pulley is at the top.
7. Apply a thin layer of sealant to the surface of the cylinder head mating with the camshaft housing.
8. Lubricate the upper part of the levers with clean engine oil.
9. Install the camshaft housing to the cylinder head.
10. Install the cylinder head bolts and tighten by hand.
11. Gradually and sequentially tighten the cylinder head bolts in accordance with the requirements specified in subsection 3.1.2.
12. Screw in bolts of fastening of a back casing of a gear belt to the case of a camshaft.
13. Install the camshaft pulley and toothed belt.
14. Connect electric sockets to components of a head of the block of cylinders.
15. Connect the coolant hose to the thermostat housing and secure with a clamp.
16. Connect manifolds.
17. Install the wheel and lower the car.
18. Check that all pipes and hoses are securely connected and add coolant to the cooling system and install the spark plugs.
19. Connect the battery, start the engine and check for leaks.
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