Attention: The following is a description of the removal for a gasoline engine. the procedure for other engines is different, before lifting the cylinder head, double check that all pipes and other connections to and from the cylinder head are disconnected. Features for the diesel engine are given at the end of the chapter.
Remove the cylinder head only when the engine is cold. The intake and exhaust manifolds remain connected.
Withdrawal
Disconnect battery ground.
Drain coolant and remove air filter.
5-cylinder engine: remove the upper part of the intake manifold.
Unscrew the alternator bracket from the cylinder head.
Remove the coolant hose from the cylinder head and intake manifold.
Remove the low pressure vacuum hoses from the exhaust manifold and carburetor. For subsequent installation, mark them with adhesive tape.
Disconnect the gas supply, do not remove the retainer.
Disconnect the cold start drive.
Disconnect the fuel supply line at the carburetor and plug it with a suitable plug.
Disconnect the plug connection of the intake manifold heating and the idle air shut-off valve. Loosen the cable ties on the cylinder head cover.
Disconnect the electrical wire and brown vacuum line from the control valve on the carburetor.
Remove the exhaust pipe from the exhaust manifold.
Remove the top toothed belt cover.
Loosen toothed belt and remove from top of camshaft.
Mark and disconnect the electrical wire from the temperature sensor.
Disconnect the spark plug caps.
Disconnect the ignition distributor vacuum hose on the carburetor.
Unscrew the sump on the cylinder head cover and set aside by plugging the tubes.
Mark and remove retainer together with cylinder head cover. Take out the oil deflector.
Loosen the cylinder head bolts with an internal toothed wrench (e.g. HAZET 990Slg-12).
Attention: Bolts must be loosened in numerical order (10 to 1) or 12 to 1.
Remove cylinder head and place on 2 wooden blocks. Remove the cylinder head gasket.
Installation
Before installing the cylinder head, clean the mating surfaces with a scraper to remove gasket residue. Ensure that no dirt gets into the piston bore. Cover holes with cloth.
Check the mating surface of the cylinder head for flatness with a steel ruler.
Permissible deviation from flatness is not more than 0.1 mm. Check with a dipstick.
Minimum machining size for cylinder head. Minimum height 4-cylinder engine a=132.6 mm, 5-cylinder engine: 132.75 mm.
Attention: The cylinder head of a diesel engine cannot be machined.
Cylinder heads with cracks between the valve seats and the first threads of the spark plug thread can be used further and can be repaired without reducing their service life if the crack width does not exceed a = 0.5 mm.
Replace cylinder head gasket.
Inscription "OBEN" (vvepx") must face the cylinder head. Install gaskets without sealant. For diesel engines, ensure that the correct cylinder head gasket is used.
To center the cylinder head, use guide mandrels. To do this, cut off the heads of two old bolts for attaching the cylinder head and cut grooves for a screwdriver.
Screw in guide pins (cut head bolts) into holes 8 and 10, for a 5-cylinder engine 9 and 10.
Rotate the crankshaft so that all pistons are at the same height.
Put on the cylinder head.
Screw in the remaining 8 or 10 cylinder head bolts with washers by hand. Bolts must be replaced.
Unscrew the guide pins with a screwdriver, insert the remaining 2 bolts with washers and tighten by hand.
Caution: Cylinder head bolts must be tightened with the utmost care. Before tightening, check the accuracy of the torque wrench. Bolts should be tightened with a cold engine.
4 cylinder engine
5 cylinder engine
The cylinder head bolts are tightened in 3 stages. Tighten the bolts at each stage in the sequence from 1 to 10 or from 1 to 12.
- 1st stage: with a torque wrench, force 40 Nm
- 2nd stage: torque wrench, force 60 Nm
- Step 3: Tighten ½ turn (180°) hard key. It is permissible to tighten 2 times by 90°.
Observe the angle of rotation when tightening. Put on the key so that the handle is again along the engine. Rotate ¼ turn (90°). Handle across the engine. Another ¼ turn (90°) crank again along the engine.
Caution: Tightening the cylinder head bolts on a hot engine (for petrol engine) is not allowed. On a diesel engine, tighten the bolts when the engine is warm.
Install toothed belt.
Caution: When installing the cylinder head repair kit with the camshaft installed, lubricate the mating surface between the poppet and cam.
Screw on the cylinder head cover with oil deflector and new gaskets to 10 Nm. At the same time, screw on the sediment bowl and the carburetor earth cable.
Install the cylinder head cover of the 5-cylinder engine and install the toothed belt cover.
Install the generator bar. Pull on the V-belt.
Install the muffler downpipe to the exhaust manifold.
Connect the electrical wires for the intake manifold heater and the idle air shutoff valve. Tighten the cable tie on the cylinder head cover. Connect the electrical wire and brown tubing to the control valve.
Connect the vacuum hoses to the intake manifold and carburetor in accordance with the marks. If required, tighten hoses with screw clamps.
Connect the gas supply.
Connect and adjust the cold start drive.
Connect the fuel supply line to the carburetor and tighten the clamp.
Fit the ignition distributor vacuum hose to the carburetor.
Connect all hoses of the ignition system and tighten the clamps. Fill in new coolant.
Connect the wire to the temperature sensor. Put on spark plug caps.
5-cylinder engine: Install upper part of intake manifold.
Install the air filter.
Check engine oil level. If the cylinder head gasket was defective, change the oil.
Connect the battery ground cable.
With the engine warm, check the coolant level. Check the tightness of the hoses and connections of the cooling system.
Check ignition timing.
Check idle adjustment.
Diesel engine
Withdrawal
Disconnect the electrical wires from the fuel shut-off valve and glow plugs.
Clean and unscrew the intake pipes on the pump and injectors. Plug the holes with appropriate plugs.
Remove glow plugs and injectors.
Installation
Depending on the size of the pistons, head gaskets of various thicknesses are installed.
When replacing, take into account the designation of the gaskets and install a new gasket only with the same designation. Black arrow = part number, white arrow = serifs.
Tighten the cylinder head bolts with the engine warm. To do this, warm up the engine and leave it to idle until the radiator fan turns on. (Oil temperature over 50°C). Tighten the bolts ¼ turn (90°) with a hard key, without first loosening or removing the key. Follow tightening sequence.
Install glow plugs.
Install injectors.
Clean the high pressure fuel line connection and tighten the union nut to 25 Nm.
Connect the electrical wires to the fuel cut-off valve and glow plugs.
Check the start of delivery of the high pressure fuel pump.
Only for the 1.6l engine: After about 1000 km after repair, the cylinder head bolts must be tightened. To do this, tighten the bolts ¼ turn (90°) with a hard key, without first loosening or removing the key. Follow tightening sequence. The bolts can be tightened on a cold or warm engine.
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