External elements of the engine
1 - top cover; 2 - ignition coil; 3 - ignition coil connector; 4 - electrical connector of the nozzle; 5 - camshaft position sensor connector; 6 - power steering pump; 7 - heater hoses; 8 - vacuum hoses; 9 - hoses of the cooling system; 10 - throttle position sensor connector; 11 - idle speed controller connector; 12 - fuel return hose; 13 - vacuum brake booster hose; 14 - oil pressure switch sensor connector; 15 - high pressure fuel hose connection; 16 - seal; 17 - gas pedal cable; 18 - ignition system sensor connector.
Cylinder head gasket setting elements
1 - radiator hose; 2 - branch pipe of the cooling system; 3 - laying of the column of the cylinder block to; 4 - rear cover of the timing belt for the camshaft drive; 5 - cylinder head; 6 - a bolt of fastening of a head of the block of cylinders; 7 - radiator hose; 8 - forced crankcase ventilation hose; 9 - cylinder head cover, 10 - gasket; 11 - semicircular insert; 12 - hose 4 of the engine ventilation system; 13 - back cover of the spongy belt; 14 - gear wheel of the exhaust camshaft; 15 - camshaft position sensor; 16 - bypass roller; 17 - exhaust pipe of the exhaust system.
Removing
Disconnect the ground wire from the battery.
Relieve fuel pressure in the fuel system.
Drain the coolant from the engine cooling system into a suitable container.
Remove the air intake hose.
Remove the camshaft drive belt Disconnect the gas pedal cable.
Remove the top cover.
Disconnect the ignition coil connectors.
Remove the ignition coil assembly.
Disconnect the electrical connectors for the throttle position sensor, idle speed control, oil pressure switch, ignition sensor, injector, and camshaft position sensor.
After loosening the clamp, disconnect the fuel return hose.
Disconnect the high pressure fuel hose and remove the O-ring.
Disconnect the vacuum brake booster hose.
Disconnect the cooling system hoses.
Disconnect heater hoses.
Remove the bracket and power steering pump assembly along with the hoses attached to it.
Tie up the removed power steering pump with wire to the car body.
Disconnect the radiator hose.
Remove the coolant supply pipe and thermostat housing assembly and gasket.
Disconnect the crankcase ventilation hose.
Remove the cylinder head cover and gasket.
Remove the semi-circular cap.
While holding the camshaft wrench, remove the camshaft sprocket mounting bolts.
Remove the exhaust camshaft gear.
After unscrewing the bolt, remove the bypass roller.
Loosen the bolt and remove the camshaft position sensor.
Loosen the bolts and remove the rear camshaft belt cover.
Remove a reception pipe and a lining of system of release of the fulfilled gases.
Gradually loosen the cylinder head bolts in 3 steps in the sequence shown in the figure, and then remove the cylinder head assembly.
Cylinder head bolt loosening sequence
Remove the cylinder head gasket.
Installation
Installation is carried out in the reverse order, taking into account the following.
Clean the mating surfaces of the cylinder block and head gasket.
Check the alignment of all holes on the gasket and the cylinder head.
Check the length of the bolt shaft, which should be no more than 96.4 mm; if this value increases, the bolt must be replaced.
1 - bolt head; 2 - places for applying engine oil; 3 - chamfer; 4 - washer; 5 - cylinder head; A - 96.4 mm.
Install the bolt washer so that the chamfered surface of the washer is on top.
Before installation, lubricate the top surface of the washer and the threads of the bolt with a small amount of engine oil.
Tighten the cylinder head bolts in several stages in the sequence shown in the figure.
- I reception: tighten with a torque of 78 Nm
- Step 2: Loosen all bolts completely in reverse order
- Step III: tighten with a torque of 20 Nm
- Step IV: Apply paint marks to the bolt heads and cylinder heads and tighten by 90°
- 5th reception: tighten another 90°. The marks on the bolts and the cylinder head must be in line
ATTENTION: Always tighten the bolt to a strictly 90°angle. Otherwise, the cylinder head bolt may be loosened. If the bolt was accidentally turned more than 90°, loosen it completely and repeat all bolt tightening operations.
When installing the exhaust camshaft sprocket, secure the sprocket against rotation with the same tool as when removing it, and tighten the sprocket mounting bolt to 38 Nm.
Before installing the cylinder head cover gasket, apply sealant to the areas indicated in the figure.
When installing the inlet pipe (1) cooling system, loosen the bolt securing the inlet pipe (arrow in fig.).
When installing the inlet and thermostat assembly, apply layers of sealant to the mating surface of the inlet.
Coat the gasket of the coolant inlet pipe with soapy water and insert the thermostat housing into the coolant pipe.
Tighten the bolts of the thermostat housing assembly and the bolt of the inlet pipe of the cooling system.
When installing the high pressure fuel hose, lubricate the O-ring with a small amount of clean engine oil.
Slightly rotate the fuel hose flange to insert it into the fuel manifold. After installation, check that the hose turns smoothly in the fuel manifold.