Contents: Removal ⇓ Installation ⇓
Caution: Allow the engine to cool completely before removing the manifold.
Removal
1. Relieve the pressure in the fuel system (see chapter 4).
2. Disconnect the negative cable from the battery.
Caution: If your vehicle has a theft-protected audio system, make sure you have the unlock code before disconnecting the battery.
3. Drain the coolant from the radiator and from the cylinder block (see chapter 1).
4. Drain the engine oil and remove the oil filter.
5. Remove the air inlet duct.
6. Remove the spark plugs.
7. Remove the intake manifold (see paragraph 8).
8. Remove the exhaust manifold (see paragraph 9).
9. Remove the cylinder head cover (see paragraph 6).
10. Remove the timing belt covers and remove the belt(s) (see paragraph 5).
11. Remove the alternator and power steering pump drive belt(s) (see chapter 1).
12. Remove the generator bracket.
13. Remove the crankshaft angle sensor and ignition distributor (or ignition coil block).
14. Loosen the bolts and remove the power steering pump without disconnecting the hoses from it. Move the pump to the side. Mark and disconnect any hoses and wiring that may interfere with cylinder head removal.
15. Loosen the bolts and remove the coolant pipe from the transmission side (figure 10.15).
16. Remove both camshafts and take out the tappets (see paragraph 7).
17. Loosen the cylinder head mounting bolts in the reverse order to that shown in Fig. 10.27. Loosen the bolts one at a time, no more than a quarter turn at a time, until they can be removed by hand. The bolts can be discarded (save only the washers for reinstallation) - when installing the head, all bolts must be replaced.
18. Lift the head from the block. If this fails, gently pry the head away from the block from the transmission side.
19. Remove from the head all parts that will interfere with its cleaning and inspection. Learn more about the cylinder head see chapter 2B.
Installation
20. Before assembly, the mating surfaces of the head and cylinder block must be absolutely clean.
21. Scrape off any remaining old gasket and carbon deposits from the surfaces. Then wash them with nitro solvent or acetone. To prevent scraped dirt from getting into the cylinders, stuff them with clean rags. When you have finished working, vacuum the cylinders to remove any dirt particles that may have gotten in despite the precautions taken. Be careful not to scratch the surface of the block, which is made of soft aluminum alloy.
22. Inspect the mating surfaces of the cylinder head and block for deep dents, scratches and other damage. If the damage is not extensive, it can be removed with a fine file, but if the damage is significant, machine processing is required for repair.
23. Tap the threaded holes in the block for the bolts using a tap of the appropriate size, then remove the chips from the holes with compressed air.
Caution: When blowing out holes with compressed air, be sure to wear safety glasses. Make sure that there is no dirt, rust, chips, sealant residue left in the threaded holes, and that the threads themselves are not damaged, since all this will prevent the head from being pressed evenly and with the required force to the block, even if the torque specified is applied to the bolt heads Technical data,
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24. Install the parts that were removed from the head onto it.
25. Place a new gasket on the block, paying attention to the markings on it, such as TOP (top) or FRONT (front side). Carefully lower the head onto the block, being careful not to move the gasket.
26. Lubricate the threads of the NEW head bolts and tighten them into the holes by hand.
27. Tighten the bolts gradually, in several passes, in the sequence shown in the figure 10.27, until the specified torque value corresponding to the 1st tightening stage is reached, then tighten it further in two passes to the specified angle (see Technical Data).
28. Further assembly is carried out in the reverse order of disassembly.
29. Fill the cooling system. Install a new oil filter and fill the engine with oil (see chapter 1).
30. Start the engine and check for leaks. Check the ignition timing (see chapter 5). Take a test drive.
31. During the first few hundred kilometers, check the coolant level frequently to ensure there are no leaks.