Withdrawal
1. Drain the coolant and disconnect the radiator supply hose.
2. Disconnect the crankcase ventilation hose from the air filter and cylinder head cover.
3. Disconnect the air intake pipe.
4. Disconnect the vacuum hose, fuel hose and coolant supply hose.
5. Remove from spark plugs tips of high-voltage wires.
6. Remove the ignition coil.
7. Remove the airbox mounting post.
8. Remove the intake manifold.
9. Remove the heat shield and exhaust manifold.
10. Remove the water pump pulley and crankshaft pulley.
11. Remove casings of a gear belt.
12. Move the toothed belt tensioner towards the water pump and temporarily secure it in this position.
13. Remove a gear belt.
14. Remove the cylinder head cover.
15. Using a special tool, in the sequence shown in the figure, remove the cylinder head bolts in 2–3 passes.
16. Remove the remnants of the gasket from the cylinder head and block.
Note. Be careful not to get particles of the gasket material into the engine cylinders.
Examination
1. Inspect the cylinder head for damage, cracks, oil and coolant leaks. If necessary, replace the cylinder head.
2. Remove scale, sealant and carbon deposits. Blow out the lubrication channels with compressed air.
3. With a metal ruler and a feeler gauge in six directions A, B... check the flatness of the cylinder head. Regrind the cylinder head if necessary.
Standard deviation from flatness:
- 1.3L engine: less than 0.03mm
- 1.1L engine: less than 0.05mm
Maximum permissible deviation from flatness:
- 1.3L engine: less than 0.08mm
- 1.1L engine: less than 0.10mm
Installation
1. Clean all mating surfaces of the cylinder block and cylinder head.
2. Install a new cylinder head gasket.
3. In the sequence shown in the figure, tighten the cylinder head bolts.
Tightening torque for fastening bolts
cylinder heads:
- 1.3 l engine: 23–27 Nm + tighten by an angle (60–62) °+ turn a corner (60–62) °
- engine 1.1 l:
- on a cold engine: 60-70Nm
- on a hot engine: 70–75 Nm
4. Pull the toothed belt tensioner towards the water pump and secure it in this position.
5. Install the toothed belt on the camshaft pulley and tighten the drive branch of the belt by turning the pulley in the opposite direction to normal. Check alignment of alignment marks.
6. Adjust the toothed belt tension.
7. Establish a cover of a head of cylinders and tighten bolts of fastening the demanded moment.
Tightening torque: 8–10 Nm
8. Establish casings of a gear belt.
9. Install a new intake manifold gasket and intake manifold. Tighten the mounting bolts to the required torque.
Tightening torque: 15–20 Nm
10. Install a new exhaust manifold gasket and exhaust manifold. Tighten the fastening nuts to the required torque.
11. Install the airbox and tighten the nuts and mounting bolts to the required torque.
Tightening torque: 15–20 Nm
12. Install the ignition coil.
13. Install the air intake duct.
14. Connect a vacuum hose, a fuel hose and a hose of a supply of a cooling liquid.
15. Connect the crankcase ventilation hose.