Withdrawal
1. Drain the coolant and disconnect the upper radiator hose.
2. Remove suction hose (between air cleaner and rocker cover).
3. Remove the air inlet hose.
4. Remove 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 toothed belt cover.
12. Move the toothed belt tensioner pulley towards the water pump and temporarily secure it.
13. Remove a gear belt.
14. Remove the rocker cover.
15. Remove the cylinder head assembly. The cylinder head bolts can be removed with a special tool, cylinder head bolt wrench (09221-11001), in the sequence shown in the figure.
16. Remove parts of a lining from the top and bottom surface of a head of the block of cylinders.
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 make sure they are not clogged.
3. Check the flatness of the cylinder head joint surface using a ruler in directions A, B, etc., as shown in the figure.
If deviations from flatness in any direction are out of range, replace the cylinder head, or lightly process 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 sealing material to the gasket and do not use old gaskets.
3. Install the cylinder head bolts. Starting from the central; 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.
Torque: Cylinder Head Bolt
- Hot engine - 70-75 Nm
- Cold engine - 80-85 Nm
4. Move the toothed belt tensioner pulley towards the water pump and temporarily secure it.
5. Install the toothed belt on the camshaft sprocket. Make sure the tension side is tight. Check that when turning the camshaft, with the tension side tightened, all alignment marks match.
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 required torque.
Tightening torque: Rocker cover bolt - 8-10 Nm
8. Install the toothed belt cover.
9. Install a new intake manifold gasket and the manifold itself.
Tighten bolts and nuts to the required torque.
Torque: Manifold bolts and nuts (descending and graduating) — 15-20 Nm
10. Install a new exhaust manifold gasket and the 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: Bolts and nuts for fastening the fuel tank - 15-20 Nm
12. Install the ignition coil.
13. Install the air inlet hose.
14. Attach the vacuum hose, fuel hose and water hose.
15. Install suction hose.