Attention: Operations and instructions applicable to all engines are given in the section on the 1.3L engine. This section only describes the differences.
Removing
Remove toothed belt and camshafts.
Disconnect the following plugs from the engine: Throttle position sensor (1), DIS ignition coils (ignition system without distributor) (2), coolant temperature sensor (3), engine wiring harness (4).
Remove generator.
Remove the bolts of the oil dipstick tube from the intake manifold and pull it together with the dipstick upwards from the oil pan.
Tag and disconnect all wires from cylinder head and intake manifold.
Loosen the bolts and remove the intake manifold from the cylinder head.
Loosen the bolts and remove the toothed belt cover holder.
Unscrew the cylinder head bolts in reverse order of numbering, i.e. from 10 to 1.
Installation
Sealing surfaces and threads or valve guides/seats must not be machined on the block head. On the sealing surface of the head, a deviation from the plane of no more than 0.05 mm is allowed, otherwise the head will need to be replaced.
Pay attention to the correct seating of both guide bushes in the cylinder block. The guide bushings should fit snugly into the number 10 and number 7 bolt holes.
Position the new cylinder head gasket so that none of the holes are blocked.
Attention: To prevent damage to 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 unlubricated cylinder head bolts. Non-new head bolts can be reused as long as they show no visible damage.
Tighten the head bolts in sequence 1 to 10 in three steps.
- Stage 1: tightening torque 15 Nm.
- Stage 2: tightening torque 30 Nm.
- Stage 3: hold out with an ordinary key by 90°.
Attention: Do not tighten the cylinder head bolts when the engine is warm as part of maintenance work or after repairs.