Replacing the cylinder head gasket

If a leak of engine oil or coolant is detected at the junction of the block head with the cylinder block, remove the head and replace its gasket. A leak can also occur due to warping of the block head due to overheating.

You will need: TORX T25 and T55 wrenches, flat blade screwdriver, pliers and side cutters.

1. Reduce the pressure in the supply system (see «Reducing the pressure in the engine power system»).

2. Remove the battery (see «Removing and installing the battery»).

3. Remove the battery tray (see «Removing and installing the battery»).

4. Drain the liquid from the engine cooling system (see «Coolant replacement»).

5. Separate the flanges of the additional muffler and the collector (see «Replacing the gasket of the collector»).



6. Remove the air supply sleeve (see «Removal and installation of the air filter»).



7. Remove the pipeline of the crankcase ventilation system (see «Cleaning the crankcase ventilation system»).




8. Compress clamps and disconnect block of a plait of wires from the coil of ignition.

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»).



Pic. 5.3. Rear Timing Belt Cover

12. Turn out three bolts of fastening of a back cover of a belt of a drive of the gas-distributing mechanism (pic. 5.3) and take it off.

13. Remove camshafts (see «Replacing camshafts»).



14. Disconnect the fuel supply line from the fuel rail by squeezing the coupling retainers.




15. Remove the fuel supply line from the holders on the rail and move the line aside.

16. Remove the ramp of the electrical connectors of the injectors (see «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 latches, disconnect the wiring harness pads from the injectors.



24. While pressing the latch, disconnect the wiring harness block from the coolant temperature sensor.

25. Remove intake pipe (see «Replacing the intake pipe gasket»).



26. Loosen the ten cylinder head bolts in the order shown in fig. 5.4, then finally unscrew the head mounting bolts and remove them together with the washers.

Attention! Bolts of fastening of a head of the block of cylinders can be turned out only on the cold engine.

27. Remove the cylinder head assembly with the collector.

Note. Removing the cylinder head is more convenient with an assistant, as it is quite heavy.

28. Remove the collector from the block head (see «Replacing the gasket of the collector»).

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;

Tighten the bolts on a cold engine in the order shown in fig. 5.5, 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 (see «Valve clearance adjustment»).

33. Adjust the tension of the timing belt (see «Replacing the timing belt»).