Replacing the cylinder head gasket.
1 - center cap, 2 - positive crankcase ventilation hose, 3 - camshaft sprocket, 4 - camshaft oil seal, 5 - front bearing cap, 6 - rear bearing cap, 7 - intake camshaft, 8 - exhaust camshaft, 9 - camshaft position sensor, 10 - camshaft position sensor mounting bracket, 11 - camshaft position sensor rotor, 12 - valve rocker, 13 - hydraulic compensator, 14 - hydraulic compensator oil flow distributor, 15 - cylinder head gasket, 16 - cylinder block.
Withdrawal
Attention:
- Cover the front fenders of the vehicle with protective covers to prevent damage to the painted surfaces of the body.
- Removing the cylinder head is done when the coolant temperature matches the ambient temperature (engine cold).
- Be careful when disconnecting hoses, do not drink oil or other liquid.
- Plug the disconnected pipes or hoses to prevent foreign particles from getting inside.
Note:
- Check the condition of the timing belt before removing the cylinder head.
- When disconnecting hoses, always mark them first so that the hoses are in their original position when connected.
1. Disconnect the wires from the battery terminals.
2. Remove the engine noise cover (if installed).
3. Remove the radiator cap, then drain the coolant.
4. Removing the air filter assembly.
- A) Disconnect the air flow sensor connector.
- b) Disconnect the air inlet hose and air duct from the air filter.
- V) Remove the three bolts securing the air filter housing.
- G) Remove the air filter.
- d) Remove the air flow sensor from the air intake hose.
Caution: Do not pull the air flow sensor by the wiring.
5. Disconnect the air intake hose from the throttle body.
6. Disconnect the accelerator pedal cable.
7. Disconnect the cooling system hoses from the throttle body.
8. Disconnect a hose of system of compulsory ventilation of a crankcase and a vacuum hose of the amplifier of brakes.
9. Disconnect vacuum hoses.
10. Remove the protective cover of the nozzles.
11. Before disconnecting the high pressure fuel hose from the fuel manifold, bleed any residual pressure from the high pressure fuel lines to prevent fuel splashing.
12. Disconnect the fuel injector harness connector.
13. Remove the fuel manifold along with the injectors.
Caution: Be careful not to drop the injectors when removing the fuel manifold.
14. Remove the intake manifold bracket.
15. Remove the intake manifold.
16. Remove the center cover from the cylinder head and the high voltage spark plug wires.
17. Disconnect the wiring connectors and wiring retainers from the cylinder head and intake manifold.
18. Remove the timing belt (see section "Timing Belt Replacement").
19. Remove the cylinder head cover and camshaft position sensor.
20. Turn away bolts of fastening and remove sprockets of camshafts.
21. Turn away bolts of fastening of covers of bearings of camshafts. Remove bearing caps, camshafts, rocker arms and hydraulic lifters.
Attention: unscrew the bolts of the bearing caps gradually, in several stages, in order to avoid deformation of the camshaft.
22. Remove the exhaust manifold heat shield.
23. Remove the exhaust manifold.
24. Remove the exhaust manifold gasket.
25. Using a special tool, unscrew the cylinder head bolts in 2-3 steps in the order shown in the figure.
Installation
Parts are installed in the reverse order of removal. Pay attention to the following operations when installing parts.
1. Installing the cylinder head and cylinder head gasket.
- A) Clean the mating surfaces for the gasket on the cylinder head and cylinder block.
- b) Check that the cylinder head gasket identification marks match the specifications.
- V) Install the cylinder head gasket on the cylinder block with the identification mark facing up (to the cylinder head).
Note: Before installing the cylinder head bolts, measure their length.
- Maximum bolt length - 99.4 mm
- G) If the cylinder head bolts have been replaced, then in the order shown in the figure, pre-tighten them to a torque of 20 Nm, then tighten by an angle of 180-184°, then completely loosen them in 2-3 steps in the reverse order.
- d) If the cylinder head gasket or cylinder head was replaced, then in the order shown in the figure, pre-tighten the bolts to 63 Nm, then loosen completely in 2-3 steps in reverse order.
- e) Tighten the cylinder head bolts in the order shown in the figure as follows:
- First tighten all bolts to 20 Nm.
- Tighten all mounting bolts at an angle of 90-94°.
- Finally tighten all mounting bolts at an angle of 90-94°.
2. Installation of manifold gaskets.
Caution: Replace the manifold gasket with a new one before reinstalling.
3. Installation of camshafts, camshaft oil seal, camshaft sprocket and cylinder head cover.
- A) Install the camshafts into the cylinder head. Do not install rocker arms.
Note:
- Apply engine oil to the bearing journals and camshaft cams.
- At the rear end of the exhaust camshaft, there are grooves for installing a camshaft position sensor.
- b) Install the camshaft bearing caps. The identification marks on the bearing caps are used to identify the location of the cap installation (intake/exhaust valve side).
- I: intake camshaft.
- E: exhaust camshaft.
- V) Check up smoothness of rotation of camshafts by hand. After checking, remove the bearing caps and install the rocker arms.
- G) Install the camshafts so that the guide pins are positioned as shown.
- d) Tighten the camshaft bearing cap bolts to the rated torque in two or three steps and in the sequence shown in the figure.
Note: Check that the rocker arm is correctly installed on the hydraulic lifter and valve stem.
- Tightening torque: 19-21 Nm
- e) With a special tool (mandrel for installing the camshaft oil seal, guide) press in the camshaft seal. Make sure that the lip and outer surface of the camshaft oil seal are lubricated with engine oil. Slide the oil seal onto the camshaft from the timing belt sprocket side, then install the oil seal until it stops with a hammer on the mandrel.
- and) Install the camshaft sprockets and tighten the mounting bolts to the specified torque.
- Tightening torque: 80-100 Nm
- h) Install the cylinder head cover. Apply sealant as shown.
Sealant:
- Region "A": Three Bond #1212D or equivalent
- Region "IN": Three Bond #1212D or equivalent
- And) Tighten the bolts "A" fixing the cylinder head cover.
- Tightening torque: 8-10 Nm
- To) Install spark plugs and ignition coils. Connect the high voltage spark plug wires and install the center cap. Tighten the bolts "IN".
- Tightening torque: 4-5 Nm
- l) Position the guide pin of the intake camshaft sprocket as shown in the illustration.
- m) Install the camshaft position sensor rotor to the exhaust camshaft, then install the camshaft position sensor mounting bracket. Tighten the sensor mounting bolt.
- Tightening torque: 10-13 Nm
4. Install the timing belt (see section "Timing Belt Replacement").
5. After completing the installation of all parts, fill in the coolant. Start the engine and check for leaks.