You will need: torque wrench, keys «at 13», «at 17», «at 19», end heads «on 10», «at 13», «at 17», hex key «on 10», screwdriver.
Attention! The head gasket is single use, so the gasket must be replaced each time the head is removed.
1. Remove the decorative engine cover (see «Removal and installation of a decorative casing of the engine»).
2. Set the piston of the 1st cylinder to the TDC position of the compression stroke (see «Setting the piston of the first cylinder to the TDC position of the compression stroke»).
3. Reduce the pressure in the power system if work is performed immediately after a trip (see «Reduced fuel pressure in the engine power system»).
4. Disconnect the wire from the terminal «minus» battery.
5. Drain the coolant (see «Coolant replacement»).
6. Remove the air filter (see «Removal and installation of the air filter»).
7. Disconnect from the throttle assembly the heating hoses, the small branch of the crankcase ventilation system, the adsorber purge, the air supply hose, the throttle position sensor and the idle speed controller (see «Removal and installation of the throttle assembly»).
8. Remove the throttle assembly (see «Removal and installation of the throttle assembly»).
9. Disconnect pads of a plait of wires from coils of ignition. Remove the ignition coils and remove the spark plugs (see «Replacement and maintenance of spark plugs»).
10. Disconnect the wiring harness connector from the emergency oil pressure drop sensor..
11.... from the coolant temperature sensor of the engine management system..
12.... and a phase sensor.
13. Loosen the clamps and disconnect the five hoses of the cooling system from the thermostat nozzles.
14. Disconnect the harness connector from the coolant temperature gauge sensor.
15. Unscrew with a key «at 13» tip mounting nut «mass» wires..
16.... and remove the wire.
17. Turn away a nut of the union of a fuel hose and disconnect it from a tube of a fuel line.
Attention! The tip of the fuel line tube is sealed with a rubber ring. Don't lose it when disassembling. Replace a heavily compressed or torn O-ring.
18. Turn out the screw of a pressure plate of an arm of fastening of a fuel line to a head of the block of cylinders and remove a plate.
19. Turn out the key «on 10» mounting bolt..
20....and disconnect «mass» wire from the head of the block.
21. Remove the intake manifold (see «Replacing the cylinder head cover gasket»).
22. Remove the head cover (see «Replacing the cylinder head cover gasket»).
23. Unscrew with a hex wrench «by 5» mounting bolts and remove the front protective cover of the timing belt...
24.... and remove the cover.
25. Hex Key «by 5» unscrew the bolts securing the lower front cover of the timing belt..
26.... and remove the cover.
27. Loosen the key «at 15» tensioner bolt...
28.... and remove the timing belt.
29. Holding the camshaft pulleys from turning, unscrew the pulley mounting bolts..
30.... remove the pulleys..
31.... and remove the keys from the grooves of the shaft shanks.
Helpful advice. To keep the camshafts from turning when unscrewing the bolts for fastening the toothed pulleys of the camshafts, we recommend using the tool shown in the photo.
Note. The intake and exhaust camshaft pulleys have the same fitting dimensions, but a disk is fixed on the intake camshaft pulley, which ensures the operation of the phase sensor.
32. Turning the key «at 15» mounting bolt, remove the tension roller.
Note. Note that there is a spacer ring under the roller.
33. Turning the key «at 15» mounting bolt, remove the support roller.
34. Key out «on 10» five bolts securing the rear protective cover of the timing belt...
35.... and remove the cover.
Pic. 5.6. The order of tightening the cylinder head bolts
36. Turn out with a hex wrench «on 10» bolts of fastening of a head of the block to the block of cylinders in an order, the return to a tightening (pic. 5.6)...
37.... and remove the block head from the engine.
Attention! Do not drive a screwdriver or other tools between the head and cylinder block.
Note. Removing the cylinder head is more convenient with an assistant, as it is quite heavy.
38. Remove the head gasket.
Note. Cylinder head bolts stretch out with repeated use. Bolts whose length (head height not included) exceeds 98 mm, replace with new ones. Before installing the block head, lubricate the bolts with a thin layer of engine oil.
39. Clean the mating surfaces of the block head and cylinder block (they must be dry and clean).
40. Remove oil from the threaded holes in the block for the head bolts.
Attention! If the oil is not removed from the threaded holes for the head bolts, cracks may appear in the cylinder block when the bolts are tightened, since the oil does not compress.
41. Check up presence of two adjusting plugs in nests of extreme openings of the block of cylinders under bolts of fastening of a head. If, when removing the head, the bushings remain in the head or come out of the sockets of the block, press them into the block until they stop.
42. Install a new head gasket on the block. The use of a used gasket is not permitted. Before installing the gasket, it is necessary to remove the oil from the mating surfaces of the block and its head. The gasket must be clean and dry. Oil contact with the gasket surface is not allowed.
43. Install the head on the block, after making sure that the crankshaft and camshafts are in the TDC position (both valves of the 1st cylinder must be closed). Tighten bolts of fastening of a head of the block in the sequence specified in fig. 5.6, in four steps:
- 1st - torque 20 Nm (2 kgf·m);
- 2nd - torque 69.4–85.7 Nm (7.1–8.7 kgf·m);
- 3rd - tighten the bolts by 90°;
- 4th - finally tighten the bolts by 90°.
44. Install the removed parts on the block head and connect hoses and wires to it in the reverse order of removal. Install the intake camshaft pulley with the disk that provides the operation of the phase sensor to the engine. Install the exhaust camshaft pulley in the same way. Adjust the timing belt tension (see «Replacing the timing belt and tensioner pulley») and alternator drive belt (see «Checking the alternator drive belt tension»).
Note. Before installing the cylinder head cover, apply sealant to the camshaft bearing housing «Loctite-574». It is allowed to start the engine no earlier than 1 hour after applying the sealant.