A cylinder head malfunction is identified by one or more of the following signs:
- low power;
- coolant leak. White exhaust gases when the engine is hot;
- high oil consumption;
- coolant entering the oil. (The oil level rises. Foam bubbles on the measuring rod. The oil is liquid, grey in colour).
- presence of motor oil in the coolant;
- lack of compression in two adjacent cylinders;
- the coolant is bubbling violently.
Installation
Before installing the cylinder head, remove any remaining seals from the cylinder head and engine block. To prevent dirt from getting into the holes in the block, cover the holes with a cloth.
Check the cylinder head bolt holes for oil. If there is, it should be removed by blotting off the oil.
Check the cylinder head and engine block for misalignment with a steel ruler, as well as misalignment in various places on the cylinder head.
Replace the cylinder head gasket.
Apply the cylinder head gasket without sealant so as not to cover the holes. The identification marking must face upwards towards the cylinder head.
Place a new gasket on the front muffler pipe.
Install the cylinder head. Make sure that the camshaft is in the TDC position of the 1st cylinder.
Tighten the 10 cylinder head bolts with washers by hand. Tighten the cylinder head bolts on a cold engine in 3-4 stages. At each stage, tighten the bolts in order from 1 to 10.
Note: It is recommended to replace the cylinder head mounting bolts.
Tightening order of head bolts for 1.6 and 1.8 liter engines
- 1st step: with a torque wrench of 20 Nm;
- 2nd step: with a torque wrench of 40 Nm;
- 3rd step: with a torque wrench of 70 Nm;
- Step 4: With a torque wrench at 90-100 Nm.
2.0L Cylinder Head Bolt Tightening Sequence
- 1st step: with a torque wrench of 30 Nm;
- 2nd step: turn to an angle of 60°;
- Step 3: Turn to an angle of 65°.
Install the muffler.
Install the camshaft and rocker arms (1.6L and 1.8L engines).
Place and secure the timing belt and timing gear onto the camshaft. Make sure that the camshaft and crankshaft are in the TDC position and that the position of the toothed belt on the toothed wheel is not lost.
Install a new cylinder head cover gasket, install the cylinder head cover and tighten the bolts alternately.
1.6L and 1.8L engines only: Figure A shows how to insert the half-round seal after applying sealant to the cylinder head mating surface and to the seal.
Figure B shows how to properly coat the cylinder head cover gasket with sealant, install it and tighten it completely.
Install the upper timing belt cover and tighten the intake manifold fitting to 25 Nm.
Check coolant, oil and low pressure hoses for porosity and tears.
Install all low pressure hoses and tighten with clamps.
Secure the wiring harness to the intake manifold.
Connect the electrical wiring to the engine.
Wet all joints with gasoline. Install and secure the fuel supply pipe with a new sealing ring. Be careful not to pinch or damage the sealing ring.
Connect the throttle cable to the throttle body and secure it to the intake manifold.
Install the ignition wires.
Install the brake booster low pressure hose and the coolant and heater hoses and secure with clamps.
Connect the air intake hose and secure with a clamp.
Place the crankcase ventilation hose onto the air intake hose and onto the cylinder head cover.
Check the engine oil level.
Adjust the throttle cable.
Connect the ground wire to the battery.
Warm up the engine to operating temperature.
Check the hose connections for leaks.
Check the ignition timing.
Check the engine operation at idle speed.
Set the clock.