External engine components removed when replacing the gasket
1 - gas cable; 2 - candle wires; 3 - throttle position sensor plug; 4 - idle speed controller plug; 5 - plug of the gas pedal position sensor; 6 - ignition distributor plug; 7 - nozzle connector; 8 - fuel return hose connection; 9 - high pressure fuel hose connection; 10 - gasket; 11 - hose connection of the vacuum brake booster; 12 - vacuum hose connection; 13 - connection of hoses of the cooling system; 14 - connection of heater hoses; 15 - bracket and power steering pump assembly.
Internal engine components removed when replacing the gasket
1 - radiator hose connection; 2 - inlet pipe and thermostat in the housing; 3 - gasket; 4 - hose for forced ventilation of the crankcase; 5 - ventilation hose; 6 - cylinder head cover; 7 - camshaft pulley; 8 - rear cover of the camshaft drive belt; 9 - downpipe of the exhaust system; 10 - gasket; 11 - bolt; 12 - sealing ring of the spark plug guide tube; 13 - cylinder head assembly; 14 - cylinder head gasket.
Removing
Disconnect the ground wire from the battery.
Relieve fuel pressure in the fuel system.
Drain the coolant from the engine cooling system.
Remove the air intake hose and camshaft drive belt.
Disconnect the throttle cable.
Remove the high voltage spark plug wires.
Disconnect the plugs of the throttle position sensor, idle speed controller, gas pedal position sensor, ignition distributor and injectors.
Loosen the clamp and disconnect the fuel return hose.
Disconnect the high pressure fuel hose and remove the gasket.
Disconnect the vacuum brake booster hose.
Disconnect the vacuum hose.
Disconnect the cooling system hoses.
Disconnect heater hoses.
Remove the bracket and power steering pump assembly with hoses.
Tie the disconnected power steering pump assembly with bracket and hoses to the car body with wire.
Disconnect the radiator hose.
Remove the inlet fitting and thermostat housing assembly.
Disconnect the crankcase ventilation hoses.
Remove the cylinder head cover.
Having fixed the camshaft pulley from turning, unscrew the mounting bolt and remove the camshaft pulley.
Remove the rear camshaft belt cover.
Remove a reception pipe and a lining of system of release of the fulfilled gases.
Turn away bolts of fastening of a head of the block of cylinders in 2 or 3 receptions in the sequence specified in drawing.
Remove the spark plug guide tube o-rings.
Remove the cylinder head assembly.
Remove the cylinder head gasket.
Examination
Check the mating surfaces of the head and cylinder block for deep scratches and other damage. If the defects are small, they can be removed by machining. But in case of significant defects, the parts must be replaced.
Using a metal ruler and feeler gauge, check the flatness of the mating surfaces.
Clean the bolt holes in the block.
Installation
Installation is carried out in the reverse order, taking into account the following:
Degrease adjacent gasket surfaces.
Check the shaft length of the bolt before installing the bolts (up to the head), which should be no more than 96.4 mm. If this dimension is exceeded, the bolt must be replaced.
Before installation, it is necessary to lubricate the upper surface of the washer and the thread of the bolt with a small amount of engine oil.
Tighten the cylinder head bolts in five steps in the sequence shown in the figure.
- I reception - tighten with a torque of 80 Nm;
- I reception - completely loosen all the bolts in the reverse order shown in the figure;
- III reception - tighten with a torque of 20 Nm;
- IV-V tricks - paint marks (on the bolt heads and cylinder head and tighten by 90°).
The marks on the bolts and the cylinder head must be in line.
WARNING: Always tighten the bolt at a strictly 90°angle, otherwise the cylinder head bolt may be loosened.
Before installing the inlet pipe of the cooling system, unscrew the bolt securing the inlet pipe and install the pipe. Screw the bolt back into place (arrow).
When installing the inlet and thermostat assembly, apply a 3 mm dia. sealant (1) on the mating surface of the inlet pipe (2).
After inserting the thermostat housing into the inlet pipe of the cooling system, tighten the bolts securing the inlet pipe of the cooling system.
When installing the camshaft pulley, secure the pulley from turning with a special tool
When installing the high pressure fuel hose (2) Lubricate O-ring 3 with a small amount of clean engine oil.
Slightly turning the fuel hose flange to the right and left, carefully insert it into the fuel manifold to prevent damage to the O-ring.
Install the camshaft drive belt.
Install the air intake hose.
Pour coolant into the cooling system.
Adjust the throttle cable.