A cylinder head failure is identified by one or more of the following:
- low power;
- coolant leak. Exhaust gases are white when the engine is hot;
- high oil consumption;
- coolant getting into the oil. (The oil level is rising. Foam bubbles on the dip stick. Liquid oil, gray).
- the presence of engine oil in the coolant;
- lack of compression in two adjacent cylinders;
- the coolant is bubbling a lot.
Installation
Before installing the cylinder head, remove any remaining seals from the cylinder head and engine block. Cover the holes with a cloth to keep dirt out of the holes in the unit.
Check for oil in the cylinder head bolt holes. If there is, it must be removed by blotting the oil.
Check the misalignment of the cylinder head and engine block with a steel ruler, as well as misalignment in various places of the cylinder head.
Replace the cylinder head gasket.
Apply the cylinder head gasket without sealant so as not to block 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.
Hand tighten the 10 cylinder head bolts with washers. Tighten the cylinder head bolts on a cold engine in 3-4 steps. At each reception, tighten the bolts in the order from 1 to 10.
Attention: It is recommended to replace the cylinder head bolts.
The order of tightening the head bolts 1.6 and 1.8 liter engines
- 1st reception: with a torque wrench of 20 Nm;
- 2nd reception: with a 40 Nm torque wrench;
- 3rd reception: with a torque wrench of 70 Nm;
- 4th reception: with a torque wrench at 90-100 Nm.
Tightening procedure for cylinder head bolts 2.0 liter engine
- 1st reception: with a 30 Nm torque wrench;
- 2nd trick: tighten by an angle of 60°;
- 3rd trick: tighten by an angle of 65°.
Install the muffler.
Install the camshaft and rocker arms (engines 1.6 l and 1.8 l).
Put on and fix on a camshaft a gear wheel with a gear belt. Make sure that the camshaft and crankshaft are in the TDC position, and the position of the toothed belt on the toothed wheel is not lost.
Apply a new cylinder head cover gasket, put on the cylinder head cover and alternately tighten the bolts.
1.6L and 1.8L engines only: Figure A shows how to insert the semi-circular seal after applying sealant to the cylinder head contact surface and seal.
Figure B shows how to properly coat the cylinder head cover gasket with sealant, install it, and finally tighten it.
Install the upper toothed belt cover and secure the intake manifold fitting with a force of 25 Nm.
Check the coolant, oil and low pressure hoses for porosity and ruptures.
Put on all low pressure hoses and tighten with clamps.
Attach the wiring harness to the intake manifold.
Connect the electrical wiring to the engine.
Moisten all connections with gasoline. Fit and secure the fuel supply pipe with a new O-ring. Be careful not to pinch or damage the O-ring.
Connect the throttle cable to the throttle body and attach to the intake manifold.
Install the ignition wires.
Put on the low pressure hose of the vacuum brake booster and the coolant and heater hoses and secure with clamps.
Connect the air intake hose and secure with a clamp.
Fit the crankcase ventilation hose to the air intake hose and to the cylinder head cover.
Check engine oil level.
Adjust the throttle cable.
Connect ground wire to battery.
Warm up the engine to operating temperature.
Check hose connections for tightness.
Check ignition timing.
Check engine idling.
Set the clock.