Tightening torque: Nm
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 oil pump with booster and bracket.
8. Remove the intake manifold.
9. Remove the heated exhaust pipe assembly.
10. Remove the water pump pulley and crankshaft pulley.
11. Remove the timing belt cover.
12. Remove the timing belt tensioner pulley.
13. Remove the timing belt.
14. Remove the cylinder head cover.
15. Remove the cylinder head assembly. The head bolts can be removed using a special tool, a cylinder head bolt wrench (09221-32001, 09221-11000), in the sequence shown in the figure.
16. Remove the gasket parts from the upper and lower surfaces of the cylinder head.
Note: Make sure that no gasket parts fall into the engine.
Examination
1. Check the cylinder head for cracks, damage, coolant leakage.
2. Completely remove scale, sealant and carbon deposits. After cleaning the oil passages, blow them out with compressed air to ensure they are not clogged.
3. Check the non-flatness of the lower surface of the cylinder head using a straight edge ruler installed 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 mating surface.
The deviation from flatness of the lower surface of the cylinder head is as follows:
- 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 head bolts in the order shown in the illustration using the tool (09221-32001, 09221-11000). Repeat the procedure, tightening the bolts to the required torque.
Tightening torque
Cylinder head bolt
- M10 – 30 Nm + (60° ~ 65°)
- M12 - 35 Nm + (60° ~ 65°)
Note. When tightening the cylinder head bolts, use a special tool and a torque wrench to tighten the bolt to the torque specified in the specification (M10: 30 Nm; M12: 35Nm), then turn the key 60-65° and repeat tightening one more time as shown in the figure.
4. Move the timing belt tensioner pulley.
5. Install the timing belt onto the camshaft sprocket. Make sure the tension side is taut. Make sure that when turning the camshaft with the tension side under tension, 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 the intake manifold itself.
Tighten the bolts and nuts to the specified torque.
Tightening torque
- Manifold bolts and nuts (inlet and outlet) — 15-20 Nm (150-200 kg/cm)
10. Install the new exhaust manifold gasket and exhaust manifold. Tighten the exhaust manifold mounting nuts to the specified torque.