Special tool
 | Socket wrench for cylinder head bolts 303-392 (21-167) |
 | Hose Clamp Remover/Installer 303-397 (24-003) |
General Equipment: Spatula.
| Name | Specification |
| Sealant remover | WSK-M2G348-A4 |
| Engine oil | WSS-M2C912-A1 |
Withdrawal
1. Disconnect the battery. See Section 414-01 for more information.
2. Relieve pressure in the fuel system. See Section 310-00A for more information.
3.
WARNING: To avoid scalding, close the coolant expansion tank filler cap with a piece of thick cloth before opening the cooling circuit. Failure to follow this instruction may result in injury.
Relieve pressure in the cooling system.
4. Raise and support the vehicle. See Section 100-02 for more information.
5. Drain the coolant from the radiator.
- Allow the coolant to drain into a suitable container.
- After draining the coolant, install the radiator drain plug.
6. Disconnect the electrical connector for the oil pressure switch.
7. Turn out the bottom bolt of fastening of an inlet collector.
8. Remove the accessory drive belt. See Section 303-05 for more information.
9. Lower the car.
10. Remove the air filter. See Section 303-12 for more information.
11. Disconnect the pipeline of the vacuum amplifier of brakes from an inlet collector. Release the quick coupling and disconnect the vacuum brake booster line.
12. Disconnect the accelerator cable from the throttle body.
13. Disconnect the vacuum hoses from the intake manifold.
14. Disconnect the plug connectors of the fuel injector wiring harness.
15. Disconnect the plug connector of the camshaft position sensor.
16.
WARNING: Fuel leakage. Observe fuel handling precautions.
Disconnect the fuel lines.
17. Disconnect the ground cable from the lift eye.
18. Remove the exhaust manifold. For more information, refer to the chapter Exhaust Manifold available in this section.
19. Disconnect the thermostat housing.
20. Disconnect the power steering pipe bracket from the cylinder head.
21. Disconnect the power steering pump bracket from the cylinder head and cylinder block.
22. Disconnect the generator.
- 1.Release the bolt.
- 2. Remove the bolt.
23. Disconnect the wiring harness from the electronic ignition coil (EI) and from the engine coolant temperature sensor (ECT).
24. Turn out the top bolt of an arm of the generator.
25. Remove camshafts.
26.
CAUTION: Cylinder head bolts can only be used twice; mark the bolts to indicate that they were used.
CAUTION: The cylinder head must be cooled to outside temperature.
NOTE: Loosen the cylinder head bolts evenly, working in the sequence shown.
Turn out bolts of a head of cylinders.
27. Remove the cylinder head.
Installation
1. Remove gasket residue using a sealant remover and spatula. Thoroughly clean the threaded holes for the cylinder head bolts.
2. Check up a head of cylinders on existence of deformation. See Section 303-00 for more information.
3. Make two guide pins as shown.
4.
NOTE: Install a new cylinder head gasket.
Install the cylinder head gasket.
- 1.Install the cylinder head gasket.
- 2.Insert the manufactured guide pins.
- 3. Check that the guide pins are installed correctly.
5. Install the cylinder head.
6.
CAUTION: Do not overtighten the cylinder head bolts.
Tighten the cylinder head bolts in three steps in the sequence shown.
- Stage 1: 20 Nm
- Stage 2: 40 Nm
- Stage 3: 90 degrees
7.
NOTE: Apply clean engine oil to the valve lifters before installing them.
Install the valve lifters.
8. Install camshafts.
9. Lower the car.
10. Connect the power steering pump bracket to the cylinder head and cylinder block.
11. Install the alternator bracket bolt.
12. Connect the wiring harness to the electronic ignition coil (EI) and engine coolant temperature sensor (ECT).
13. Connect the generator.
14. Connect the power steering pipe bracket to the cylinder head.
15.
NOTE: Install a new thermostat housing gasket.
Install the thermostat housing.
16. Connect fuel lines.
17. Connect the plug connector of the camshaft position sensor (CMP).
18. Connect the plug connectors of the fuel injector wiring harness.
19. Connect the accelerator cable and speed control cable (in the presence of) to the throttle body.
20. Connect the vacuum hoses to the intake manifold.
21. Connect the pipeline of the vacuum amplifier of brakes to an inlet collector.
22. Install the exhaust manifold. For more information, refer to the chapter Exhaust Manifold available in this section.
23. Install the intake manifold lower bolt.
24. Connect the plug connector of the oil pressure switch.
25.
NOTE: Install a new oil filter.
Drain the engine oil.
26. Lower the car.
27. Install the air filter. See Section 303-12 for more information.
28. Fill the engine with engine oil.
29. Fill in cooling liquid in the cooling system and remove air from the system. See Section 303-03 for more information.
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