Contents: Removal ⇓ Installation ⇓
Note: Operations and instructions applicable to all engines are given in the section dedicated to the 1.3L engine. This section describes only the differences.
Removal
Remove the timing belt and camshafts.
Disconnect the following plugs from the engine: throttle position sensor (1), DIS ignition coil (distributorless ignition system) (2), coolant temperature sensor (3), engine wiring harness (4).
Remove the generator.
Unscrew the bolts of the oil dipstick tube from the intake manifold and pull it out together with the dipstick from the oil pan upwards.
Mark and disconnect all wires from the cylinder head and intake manifold.
Loosen the bolts and remove the intake manifold from the cylinder head.
Loosen the bolts and remove the timing belt cover holder.
Unscrew the cylinder head bolts in reverse order of numbering, i.e. from 10 to 1.
Installation
The sealing surfaces and threads or valve guides/seats on the cylinder head must not be machined. The sealing surface of the head must be off-plane by no more than 0.05 mm, otherwise the head must be replaced.
Pay attention to the correct fit of both guide bushings in the cylinder block. The guide bushings should fit tightly in the holes for bolts number 10 and 7.
Position the new cylinder head gasket so that no holes are blocked.
Caution: To prevent damage to the valves and pistons, before installing the head, turn the crankshaft so that the piston of the first cylinder is approximately 20 mm before TDC.
Install the cylinder head and screw in the ungreased cylinder head bolts. Used cylinder head bolts can be reused if they are not visibly damaged.
Tighten the cylinder head bolts in sequence from 1 to 10 in three stages.
- Stage 1: tightening torque 15 Nm.
- Stage 2: tightening torque 30 Nm.
- Step 3: tighten with a regular wrench by 90°.
Caution: Tightening the cylinder head bolts when the engine is warm during maintenance or after repairs is not permitted.