You need: torque wrench, long T55 internal gear wrench (for four-cylinder engine) or TORX key E14 (for six-cylinder engine) and a new gasket.
Dismantling
Four cylinder engine
1. Bring the front of the car to the service position (chapter Body parts).
2. Remove the viscous fan.
3. Remove the V-ribbed and V-ribbed belts, unscrew the belt tensioner.
4. Drain the coolant through the radiator drain plug.
5. Remove the connector on the fresh air flow sensor, the carbon filter solenoid valve and the ignition power output stage (only 1.8L engine).
6. Unscrew the air filter housing assembly, dismantle the air hose to the throttle valve.
7. Remove the engine lining and unscrew the cylinder head cover
8. Unscrew a branch pipe of a cooling liquid with the gauge of the temperature behind a head of the block of cylinders.
9. Unscrew a broad tank with a cooling liquid.
10. Disconnect the connectors on all injection valves and on the Hall sensor.
11. On a 1.6L engine, remove all spark plug connectors and high voltage wire.
12. Unscrew the intake manifold brackets.
13. Unscrew the intake manifold from the cylinder head and set aside.
14. Disconnect the wire connector to the lambda probe, expose the wire.
15. Unscrew the exhaust pipe in front of the knee and press back.
16. Remove the toothed belt cover and set the piston of cylinder No. 1 to the TDC position of the ignition moment, see the chapter above.
17. Loosen the tension roller mounting bolt.
18. Mark the direction of movement of the toothed belt for subsequent assembly and remove it.
19. Loosen the cylinder head bolts in reverse order according to the tightening pattern from right to bottom.
Dismantling
Six-cylinder engine
1. Unscrew the engine cover and ribbed belt cover.
2. Remove V-ribbed and toothed belts (see section Generator).
3. Unscrew the exhaust pipe from the elbow.
4. Drain the coolant through the engine and radiator drain plug.
5. Unscrew the air hose between the fresh air flow sensor and the intake manifold.
6. Disconnect the connector from the Hall sensor.
7. Disconnect ventilation of a crankcase on a head of the block of cylinders at the left and on the right.
8. Remove the vacuum hose on the throttle valve on the left.
9. Remove the suction silencer cover from the clips and unscrew both screws under the cover.
10. Press the silencer back and lift up.
11. Remove the vacuum pipeline at the noise absorber on the left, remove the noise absorber.
12. Unscrew the cover on the left of the injection valve pipeline.
13. Remove the throttle retainer from the clips, hang the throttle and set it aside.
14. Disconnect the intake air temperature sensor connector and idle speed stabilization valve.
15. Disconnect the supply and return fuel lines.
16. Unscrew the ground connection behind the throttle valve.
17. Disconnect the vacuum hose to the control unit in front of the throttle valve.
18. Disconnect the throttle connector.
19. Unscrew the vacuum hose to the carbon filter solenoid valve. Remove the solenoid valve.
20. Disconnect all spark plug connectors.
21. Disconnect all electrical connectors for injection valves.
22. Disconnect the knock sensor and lambda probe heating connectors.
23. Disconnect the lambda probe connectors and set aside the wires.
24. Disconnect the oil pressure sensor and oil temperature sensor connectors.
25. Remove the injection valve connectors on the left and right.
26. Unscrew the hydraulic hose bracket from the intake manifold. Do not disconnect the hydraulic hose.
27. Unscrew the intake manifold and remove it.
28. Cover the holes with a clean cloth.
29. Unscrew a tube of giving of a cooling liquid on a head of the block of cylinders behind.
30. Remove the lambda probe.
31. Unscrew a heat-shielding screen of a final collector.
32. Unscrew a head of the block of cylinders.
33. Remove the rear toothed belt cover.
34. Unscrew a hose of a broad tank with a hydraulic liquid to the pump at a head of the block of cylinders.
35. Loosen the cylinder head bolts in reverse order as shown below. To do this, you need to cool the engine, as a hot cylinder head can be deformed after dismantling.
36. Raise the cylinder head. If it does not separate immediately, light tapping with a synthetic hammer will help.
Checking the dismantled cylinder head
For all engines
1. Remove the old gasket. The sealing surfaces of the cylinder head and engine block must be absolutely clean and free of gasket residue. Do not scratch the soft sealing surface of the cylinder head with a sharp tool. Notches can cause damage to the cylinder head gasket in the future.
2. Check the cylinder head for deformation (especially important if the gasket is damaged due to overheating).
3. Lay a long metal ruler or a guaranteed flat metal angle along the cleaned sealing surface of the cylinder head.
4. Check with a template if there is a gap of more than 0.1 mm in any place. In this case, the cylinder head must be ground before assembly.
5. The cylinder head can only be modified within certain limits. Its minimum height, measured from the top to the bottom of the sealing surface, should be 139.25 mm in a four-cylinder engine and 132.75 mm in a six-cylinder engine.
Installation
For all engines
1. If the cylinder head is being changed, then the hydraulic pusher guides should be lightly lubricated with oil. This also applies to cylinder heads with a camshaft already installed.
2. If necessary, install the cap on the replacement head of the six-cylinder engine.
3. The threads of the cylinder head bolts and the holes on the engine block must be clean and undamaged, otherwise the tightening torque may be distorted when the bolts are tightened.
4. There must be no water or oil in the threaded holes on the engine block, otherwise the cast material may break in the area of the threaded holes.
5. Rotate the crankshaft slightly in the opposite direction of rotation so that neither piston is at TDC, otherwise the open valve may collide with the piston when the cylinder head is installed. This must also be observed during the subsequent installation of the toothed belt.
6. Lay the cylinder head gasket on the engine block so that the part number or designation «up» were facing the cylinder head.
7. Install the cylinder head. At the same time, pay attention to the centering pins and fitted bushings.
8. First tighten all the cylinder head bolts by hand and then tighten them in the sequence shown below:
Engine
|
Four-cylinder
|
Six-cylinder
|
1st tightening stage |
40 Nm
|
(No)
|
2nd tightening stage |
60 Nm
|
60 Nm
|
3rd tightening stage | Tighten the bolts evenly with a hard wrench by half a turn further (same sequence). This can also be done three quarter turn |
9. In this way, all the bolts are completely screwed.
Important: Follow the tightening sequence when installing the intake manifold of a six-cylinder engine.
10. Mount the toothed belt.
11. In addition, in a four-cylinder engine with a displacement of 1.6 liters, check the ignition setting (chapter Ignition system).
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