You will need: All the tools needed to remove the battery (cm. «Removing and installing the battery») and her shelves (cm. «Removal and installation of the shelf of fastening of the rechargeable battery»), cylinder head cover (cm. «Replacing the cylinder head cover gasket»), timing belt drive (cm. «Replacing the timing belt»), camshafts (cm. «Replacing camshafts»), collector (cm. «Removal, installation of the collector and replacement of its gasket»), as well as TORX T25 and T55 wrenches, a flat-blade screwdriver, pliers, side cutters.
1. Reduce the pressure in the supply system (cm. «Reducing the pressure in the power system»).
2. Remove the battery (cm. «Removing and installing the battery»).
3. Remove the battery tray (cm. «Removal and installation of the shelf of fastening of the rechargeable battery»).
4. Drain the liquid from the engine cooling system (cm. «Coolant replacement»).
5. Remove air sleeve (cm. «Removing and installing the air filter and intake silencer»).
6. Remove the pipeline of the crankcase ventilation system (cm. «Cleaning the crankcase ventilation system»).
7. Compress clamps and disconnect block of a plait of wires from the coil of ignition.
8. Remove all spark plugs (cm. «Replacement and maintenance of spark plugs»).
9. Remove the cylinder head cover (cm. «Replacing the cylinder head cover gasket»).
10. Remove the timing belt (cm. «Replacing the timing belt»).
Pic. 5.5. Rear Timing Belt Cover
11. Turn out three bolts of fastening of a back cover of a belt of a drive of the gas-distributing mechanism (pic. 5.5) and take it off.
12. Remove camshafts (cm. «Replacing camshafts»).
13. Remove the collector (cm. «Removal, installation of the collector and replacement of its gasket»).
14. Disconnect the fuel supply line from the fuel rail by squeezing the coupling retainers.
15. Turn out two screws of fastening of holders of the pipeline of giving of fuel and take the pipeline aside.
16. Remove the ramp of the electrical connectors of the injectors (cm. «Removal and installation of the fuel rail»).
17. Turn out the screw of fastening of an arm of the indicator of level of oil.
18. Disconnect from an inlet pipe hoses of the vacuum amplifier of brakes and the valve of a purge of an adsorber.
19. Squeezing the clamps with pliers and sliding them along the hoses, disconnect the radiator hose from the outlet pipe of the water jacket..
20.... and the interior heater hose.
21. Slide up the latch..
22.... and disconnect the wiring harness block from the throttle assembly cover.
23. Squeezing the latch, disconnect the wiring harness block attached to the cylinder head bracket.
24. Use side cutters to cut the plastic clamps that secure the wiring harness to the cylinder head bracket.
NOTE: Clamps are disposable. When assembling, install new clamps.
25. While pressing the latch, disconnect the wiring harness block from the coolant temperature sensor.
Pic. 5.12. Bolts of fastening of an inlet pipe
26. Turn out two lower bolts of fastening of an inlet pipe (see fig. 5.12).
Pic. 5.6. The procedure for loosening the cylinder head bolts
27. Loosen the ten cylinder head bolts in the order shown in fig. 5.6, and then finally unscrew the head mounting bolts and remove them together with the washers.
WARNING: The cylinder head bolts must only be removed when the engine is cold.
28. Remove the cylinder head assembly with the intake pipe and throttle assembly and the gasket installed under it.
USEFUL ADVICE: It is more convenient to remove the cylinder head with an assistant, as it is quite heavy.
29. Clean the mating surfaces of the head and block.
30. Check up a head of the block on lack of a buckling. To do this, placing the ruler with an edge on the surface of the head, first in the middle along, then across and diagonally, measure the gap between the plane of the head and the ruler with a feeler gauge. Replace the cylinder head if the clearance is greater than 0.1mm.
31. Install the cylinder head in the reverse order of removal, taking into account the following:
- remove oil or coolant from the threaded holes of the cylinder head bolts that got there when the head was removed;
- be sure to install a new head gasket, its reuse is not allowed;
- lubricate the bolts with engine oil;
Pic. 5.7. The order of tightening the cylinder head bolts
– Tighten bolts on the cold engine in the order shown in fig. 5.7, in three steps:
- Step 1 - Torque 15.0 Nm (1.5 kgf·m);
- Step 2 - Tighten to 30.0 Nm (3.0 kgf·m);
- Step 3 - Tighten 90°.
32. Establish all removed details and knots in an order, the return to removal. After installing the camshafts and the timing belt, check and, if necessary, adjust the clearances in the valve drive (cm. «Valve clearance adjustment»).
33. Adjust the tension of the timing belt (cm. «Replacing the timing belt»).
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