You will need: TORX T25 and T55 keys, a flat-blade screwdriver, pliers and side cutters.
1. Reduce the pressure in the fuel system (see "Decreased pressure in the engine fuel system").
2. Remove the battery (see "Removal and installation the battery").
3. Remove the battery tray (see "Removal and installation the battery").
4. Drain the fluid from the engine cooling system (see "Replacing the coolant").
5. Disconnect the flanges of the additional muffler and the exhaust manifold (see "Replacing the catalytic converter gasket").
6. Remove the air supply hose (see "Removal and installation the air filter").
7. Remove the crankcase ventilation system pipe (see "Cleaning the crankcase ventilation system").
8. Squeeze the clips and disconnect the wiring harness connector from the ignition coil.
9. Remove all spark plugs (see "Replacement and maintenance of spark plugs").
10. Remove the cylinder head cover (see "Replacing the cylinder head cover gasket").
11. Remove the timing belt (see "Replacing the timing belt").
Fig. 5.3. Gas distribution mechanism drive belt back cover
12. Unscrew the three bolts securing the rear timing belt cover (Fig. 5.3) and remove it.
13. Remove the camshafts (see "Replacing camshafts").
14. Disconnect the fuel supply line from the fuel rail by squeezing the clamps of the connecting sleeve.
15. Remove the fuel supply line from the holders on the rail and move the line to the side.
16. Remove the injector electrical connector rail (see "Removal and installation the fuel rail").
17. Remove the screw securing the oil level indicator bracket.
18. Disconnect the brake booster and purge valve hoses from the intake pipe.
19. Using pliers, squeeze the clamps and slide them along the hoses, disconnect the radiator hose from the water jacket outlet pipe…
20. …and the interior heater hose.
21. Slide the lock up…
22. …and disconnect the wiring harness connector from the throttle body cover.
23. By squeezing the clamps, disconnect the wiring harness blocks from the injectors.
24. Press the lock and disconnect the wiring harness connector from the coolant temperature sensor.
25. Remove the intake pipe (see "Replacing the intake manifold gasket").
Fig. 5.4. Procedure for loosening the cylinder head mounting bolts
26. Loosen the ten cylinder head mounting bolts in the order shown in Fig. 5.4, then completely unscrew the head mounting bolts and remove them together with the washers.
Attention! The cylinder head mounting bolts can only be removed when the engine is cold.
27. Remove the cylinder head assembly with the exhaust manifold.
Note: It is more convenient to remove the cylinder head with an assistant, as it is quite heavy.
28. Remove the catalytic converter from the cylinder head (see "Replacing the catalytic converter gasket").
29. Clean the mating surfaces of the head and block.
30. Check the cylinder head for warpage. To do this, place a ruler edgewise on the surface of the head, first in the middle along, then across and diagonally, and measure the gap between the plane of the head and the ruler with a feeler gauge. Replace the cylinder head if the gap is greater than 0.1 mm.
31. Install the cylinder head in the reverse order of removal, taking into account the following:
- remove any oil or coolant that got into the threaded holes of the cylinder head mounting bolts when removing the head;
- be sure to install a new cylinder head gasket, it cannot be reused;
- lubricate the bolts with engine oil;
Fig. 5.5. Cylinder head bolt tightening sequence
Tighten the bolts on a cold engine in the order shown in Fig. 5.5, in three stages:
- Step 1 - Tighten to 15.0 Nm (1.5 kgf·m);
- Step 2 - Tighten to 30.0 Nm (3.0 kgf·m);
- Step 3: Turn it to a 90° angle.
32. Install all removed parts and assemblies in the reverse order of removal. After installing the camshafts and timing belt, check and, if necessary, adjust the valve clearances (see "Adjusting valve clearances").
33. Adjust the timing belt tension (see "Replacing the timing belt").