Start work only after the engine has completely cooled down!
Removing
1. Disconnect and remove the battery (see chapter Engine electrical equipment).
2. Empty the cooling system (see chapter Cooling, heating systems).
3. Turn out the spark plugs and remove the accessory drive belt (see chapter Current service).
4. Remove the timing belt (see Removing and installing timing belt).
5. Turn out fixing bolts and remove an arm of fastening of the engine from the right side of a head of cylinders.
6. Remove the intake piping and exhaust manifold (see chapter Power and exhaust systems). If the cylinder head is not serviceable, it can be removed complete with pipeline and manifold:
7. Disconnect the wiring from the throttle position potentiometer, idle speed control (ISC), fuel injection injectors, EGR valve (EGR), carbon adsorber purge valve and lambda probe.
8. Relieve pressure in the power supply system and disconnect the fuel lines from the fuel line. Disconnect also all vacuum hoses and hoses of the cooling system from the inlet pipe/throttle body.
9. Remove the support bracket from the intake manifold, also remove the upper alternator mounting bracket.
10. Disconnect the accelerator cable.
11. Disconnect from a final collector a reception pipe of system of release of the fulfilled gases in gathering with a basic arm.
12. Disconnect the electrical wiring from the lambda probe.
- Remove the timing cover (see Removal and installation of a cover of the gas-distributing mechanism).
- Remove the camshaft gear (see Removal and installation of the timing belt tensioner and timing gears).
- Turn out bolts of fastening of a back cover of a drive of GRM to the case of the timing mechanism.
- Disconnect the wiring from the ignition module, coolant temperature sensor (ECT), knock sensors (KS) and crankshaft position (CKP). Loosen the ground bus mounting bolt at the front of the head and remove the electrical wiring protection cover from the head.
- Release fastening collars and disconnect hoses of system of cooling from a casing of the thermostat.
- Make sure that all hoses, pipes, wires and other communication lines are disconnected and do not interfere with the removal of the cylinder head.
13. Acting in the reverse order shown, gradually, a quarter of a turn per approach, loosen the cylinder head bolts so that they can be turned out manually. Remove the head bolts complete with your washers.
14. Lifting up, separate the gas distribution mechanism housing from the head - if necessary, tap the housing from the sides with a soft-faced hammer.
In no case do not pry the case with a lever in order to avoid damage to the mating surfaces! Mark the position of the two guide bushings, remove them from the head and put them in a safe place.
15. Separate the cylinder head from the block - try not to drop the valve drive levers and oil seals. If necessary, lightly tap the head from the sides with a soft-faced hammer - in no case DO NOT Pry it with a lever (see warning above)! Mark the position of the two guide bushings, remove them and put them in a safe place.
16. Remove the gasket—do not discard the gasket yet to identify a new one.
Preparing for installation
1. Thoroughly clean and dry the mating surfaces of the head and cylinder block. Use a hard plastic or wood scraper to remove all traces of old gasket material and carbon deposits. Also clean the piston bottoms. Be extremely careful - surfaces are easily damaged. Remember that dirt should not get into the oil channels, water galleries, channels and threaded holes - plug them with plugs or seal them with tape. To prevent deposits from getting into the gaps between the pistons and cylinders, fill the last with a thick lubricant, which, after cleaning, can be easily removed with a stiff brush. After cleaning, wipe all surfaces with a clean, dry cloth.
2. Inspect the mating surfaces of the head and block for deep scratches, cracks, or other damage. Minor defects can be eliminated with a small scraper, in more serious cases, the head should be machined or replaced.
3. Make sure the threaded holes are clean and dry - just in case, blow them out with compressed air (you can use a bicycle pump). The presence of traces of grease in the blind holes can lead to the destruction of the block when the bolts are tightened as a result of the increase in hydraulic pressure.
4. Head bolts must be replaced without fail, regardless of their current condition.
5. Using a steel ruler and a blade-type feeler gauge, check the flatness of the mating surface of the head (see General and overhaul of the engine).
6. Replace the cylinder head bolts - the bolts must be replaced without fail, regardless of their current condition.
Installation
1. Bring the piston of the first cylinder to the TDC position of the end of the compression stroke.
2. Wipe dry the mating surfaces of the block and head with a clean rag.
3. Make sure both guide bushings are in place.
4. Lay a new sealing gasket on the mating surface of the cylinder block, - the gasket is placed with the marking «OBEN/TOP» up.
5. Install the head on the cylinder block - make sure that the guide bushings fit into the receiving sockets.
6. Wipe dry with a clean rag the mating surfaces of the head and the timing housing. Make sure that the valve levers, oil seals and hydraulic compensators are installed correctly.
7. Apply a coat of suitable sealant (consult a service station) on the upper mating surface of the cylinder head.
8. Install the guide bushings and lubricate the valve drive levers with clean engine oil.
9. Carefully install the timing housing (with embedded camshaft) on the cylinder head, make sure that the guide bushings get into the receiving sockets correctly, - make sure that the guide bushings get into the receiving sockets correctly.
10. Place washers on the NEW timing case/cylinder head bolts, then install the bolts and finger-tight.
11. Working in a strictly defined sequence, in several steps evenly, tighten the bolts with the force of the 1st stage.
12. In the same order, tighten the bolts to the corners, first the 2nd, then the 3rd and 4th stages, use the goniometer nozzle, or apply reference marks with paint or a marker.
13. Screw in the bolts of the rear timing cover and tighten them to the required force.
14. Make sure that the bracket of the right suspension support of the power unit is correctly installed and tighten the bolts of its fastening with the required force.
15. Install the camshaft gear (see Removal and installation of the timing belt tensioner and timing gears) and timing belt (see Removing and installing timing belt).
16. Restore the original wiring connection, make sure that the harnesses are routed correctly and that they are securely fastened in all provided intermediate clamps.
17. Connect the hoses of the cooling path to the thermostat housing - make sure that the fixing clamps are tightened securely.
18. Reinstall intake manifold and exhaust manifold (see chapter Power and exhaust systems).
19. Reinstall the crankcase guard and right front wheel. Lower the vehicle to the ground and tighten the wheel bolts to the correct torque.
20. Make sure that all hoses are connected correctly and securely, then charge the cooling system (see chapter Cooling, heating systems).
21. Connect the battery.
22. Start the engine and check it for signs of developing fluid leaks.
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