Removal
1. Drain the coolant and disconnect the upper radiator hose.
2. Remove the suction hose (between the air cleaner and the rocker cover).
3. Remove the air inlet hose.
4. Remove the vacuum, fuel and water hoses.
5. Disconnect the wires from the spark plugs.
6. Remove the ignition coil.
7. Remove the fuel tank.
8. Remove the intake manifold.
9. Remove the exhaust pipe assembly.
10. Remove the water pump pulley and crankshaft pulley.
11. Remove the timing belt cover.
12. Move the timing belt tensioner pulley towards the water pump and temporarily secure it.
13. Remove the timing belt.
14. Remove the rocker arm cover.
15. Remove the cylinder head assembly. The cylinder head bolts can be removed using a special tool, a cylinder head bolt wrench (09221-11001), in the sequence shown in the figure.
16. Remove the gasket parts from the upper and lower surfaces of the cylinder head.
Examination
1. Check the cylinder head for cracks, damage, coolant leakage.
2.. Completely remove scale and carbon deposits. After cleaning the oil valves, blow them out with compressed air to ensure that they are not clogged.
3. Check the non-flatness of the cylinder head joint surface using a ruler in directions A, B, etc., as shown in the figure.
If the flatness deviations in any direction are outside the established limits, replace the cylinder head or lightly treat its surface.
Deviation from the plane of the lower surface of the cylinder head:
- Nominal value less than 0.05 mm
- Limit - 0.1 mm
Installation
1. Clean the surfaces of the cylinder block and cylinder head that come into contact with the gasket installed between them.
2. Install a new gasket on the cylinder head. Do not apply sealant to the gasket or use old gaskets.
3. Install the cylinder head bolts. Starting with the center; top bolt, tighten all cylinder head bolts in the order shown in the figure using the special tool (09221-11001). Repeat the procedure, tightening the bolts to the required torque.
Tightening torque: Cylinder head bolt
- Hot engine - 70-75 Nm
- Cold engine - 80-85 Nm
4. Move the timing belt tensioner pulley towards the water pump and temporarily secure it.
5. Install the timing belt on the camshaft sprocket. Make sure the tension side is tight. Check that when turning the camshaft with the tension side tight, all timing marks are aligned.
6. Adjust the belt according to the instructions in the section "Toothed belt".
7. Install the rocker arm cover and tighten the bolts to the specified torque.
Tightening torque: Rocker cover bolt - 8-10 Nm
8. Install the timing belt cover.
9. Install the new intake manifold gasket and manifold itself.
Tighten the bolts and nuts to the specified torque.
Tightening torque: Collector bolts and nuts (drain and exhaust) - 15-20 Nm
10. Install a new exhaust manifold gasket and manifold itself. Tighten the exhaust manifold mounting nuts to the specified torque.
11. Install the fuel tank and tighten the bolts and nuts to the specified torque.
Tightening torque: Fuel tank mounting bolts and nuts - 15-20 Nm
12. Install the ignition coil.
13. Install the air inlet hose.
14. Connect the vacuum hose, fuel hose and water hose.
15. Install the suction hose.