Removal the cylinder head
1. Disconnect the negative terminal from the battery.
2. Drain the coolant from the cylinder block and radiator.
3. Disconnect the cables, remove the control cable mounting bracket by unscrewing the two bolts.
Note: Before disconnecting the automatic transmission control cable, mark it with a marker (or measure with a caliper) its regulation (position of nuts).
4. Remove the generator.
- a) Disconnect the wire harness clamp from the clamp on the generator.
- b) Disconnect the generator connector.
- c) Remove the rubber cap and unscrew the wire fastening nut, disconnect the generator wire.
- d) Loosen the lock bolt (models with air conditioning), adjusting bolt and hinge bolt.
- d) Remove the alternator drive belt
- e) Remove the adjustment lock bolt (models with air conditioning) or adjusting bolt (models without air conditioning) and the hinge bolt.
- g) Remove the generator.
5. Remove the distributor.
- a) Disconnect the two distributor connectors.
- b) Disconnect the high-voltage wires by the rubber caps. Do not pull the wires.
Note: Pulling or bending wires may cause internal damage.
- c) Unscrew the two bolts and remove the distributor.
5. Remove the exhaust manifold.
- a) Remove the five bolts and the upper heat shield.
- b) Unscrew the bolts, nuts and remove the exhaust manifold bracket and the inlet pipe.
- c) Unscrew the six nuts, remove the exhaust manifold and gasket.
- d) Unscrew the three bolts and remove the lower heat shield.
6. Remove the coolant outlet pipe.
- a) Disconnect the following connectors:
- (1) Coolant temperature gauge sensor connector
- (2) Coolant temperature sensor connector.
- (3) Oil pressure sensor connector.
Removing and installing the cylinder head. 1 - engine wiring harness, 2 - insulator, 3 - injector, 4 - sealing bushing, 5 - ring seal, 6 - spacer, 7 - fuel manifold, 8 - gasket, 9 - EGR solenoid valve (models with EGR system), 10 - vacuum tube, 11 - fuel supply hose, 12 - intake chamber assembly with manifold, 13 - exhaust gas recirculation valve and vacuum modulator (models with EGR system), 14 - throttle cable bracket, 15 - throttle body, 16 - intake manifold bracket #2, 17 - left engine lift hook, 18 - intake manifold bracket #1, 19 - fuel pressure pulsation damper, 20 - distributor, 21 - spark plug, 22 - coolant outlet, 23 - coolant bypass tube, 24 - upper heat shield, 25 - exhaust manifold, 26 - lower heat shield, 27 - exhaust manifold bracket.
Disassembling the cylinder head. 1 - cylinder head cover, 2 - spark plug tube seal, 3 - spark plug, 4 - gasket, 5 - adjusting washer, 6 - tappet, 7 - crackers, 8 - valve spring plate, 9 - valve spring, 10 - oil scraper cap, 11 - spring seat, 12 - valve guide, 13 - valve, 14 - intake camshaft, 15 - exhaust camshaft, 16 - segment plug, 17 - oil pressure sensor, 18 - cylinder head, 19 - cylinder head gasket, 20 - timing belt, 21 - tension roller spring, 22 - tension roller, 23 - right engine mount support, 24 - generator bracket and right engine lift bracket, 25 - gasket, 26 - timing belt cover #2, 27 - clamps, 28 - timing belt cover #3, 29 - wire harness guard, 30 - camshaft position sensor, 31 - camshaft position sensor connector, 32 - segment plug, 33 - spring ring, 34 - exhaust camshaft auxiliary gear, 35 - spring washer, 36 - retaining ring, 37 - camshaft toothed pulley, 38 - camshaft oil seal, 39 - camshaft bearing cap.
Note: Mark all hoses with paint before removal for proper installation.
- b) Disconnect the following hoses:
Note: Mark all hoses with paint before removing for proper installation
- (1) Upper radiator hose;
- (2) Coolant bypass hose;
- (3) Heater hose;
- (4) Coolant supply hose to idle speed control valve;
- (5) Two fuel vapor recovery system hoses (if installed).
- c) Unscrew the two nuts, remove the coolant outlet pipe and gasket.
7. Remove the coolant bypass tube.
- a) Disconnect the following hoses:
- (1) Idle Air Control Valve Coolant Bypass Hose from Coolant Bypass Tube.
- (2) Heater hose from coolant bypass pipe.
- (3) (Models with oil cooler) Two coolant bypass hoses from the oil cooler.
- b) Unscrew two bolts and two nuts.
- c) Disconnect the coolant bypass pipe from the coolant pump cover and remove it.
- d) Remove the gasket and O-ring.
8. Remove the throttle body.
- a) Disconnect the following connectors:
- (1) Throttle position sensor connector.
- (2) Idle speed control valve connector.
- b) Disconnect the following hoses:
- (1) Crankcase ventilation hose from throttle body.
- (2) (Models with exhaust gas recirculation system) Two vacuum hoses from the throttle body.
- (3) (Models with fuel vapor recovery system) Vacuum hose from the throttle body.
- (4) Vacuum hose from the tube.
- c) Unscrew four bolts or two bolts and two nuts.
- d) Remove the throttle body and gasket.
9. Remove the left engine lifting hook and intake manifold bracket No.2 by unscrewing the bolt and nut.
10. (Models with EGR system) Remove the EGR valve and vacuum modulator.
- a) Disconnect the following hoses:
Note: Mark all hoses with paint before removal for proper installation.
- (1) Vacuum hose from channel "E" of the EGR solenoid valve.
- (2) Vacuum hose from channel "G" of the EGR solenoid valve.
- b) Loosen the union nut of the EGR pipe. Unscrew the two nuts and remove the EGR valve, vacuum modulator, vacuum hoses and gasket.
11. Remove bracket No.1 of the intake manifold by unscrewing 2 bolts.
12. Disconnect the following connectors and wire:
- (1) Knock sensor connector;
- (2) (Models with EGR system) exhaust gas recirculation electropneumatic valve connector;
- (3) ground wire.
13. Remove the vacuum tube.
Note: Mark all hoses and tubes with paint before removal for proper installation.
- a) Disconnect the following hoses:
- (1) Vacuum hose from fuel pressure regulator.
- (2) vacuum hose from the gas filter.
- (3) Air hose of the power steering pump air bypass control valve from the intake manifold.
- (4) Air hose of the idle speed increase valve when the air conditioner is turned on from the vacuum tube.
- (5) two vacuum hoses of the power steering pump air bypass control valve from the air tube.
- b) Unscrew the two bolts and the vacuum tube.
14. Disconnect the fuel supply hose from the fuel manifold, after releasing the pressure from the fuel tank.
- a) Disconnect the engine wiring harness clamp from the bracket.
- b) Using the special tool, loosen the fuel pressure pulsation damper.
- c) Remove the fuel pressure pulsation damper and two gaskets and disconnect the fuel supply hose from the fuel rail.
15. Disconnect the fuel return hose from the fuel return line.
16. (Models with EGR system) Remove the EGR valve by unscrewing the bolt.
17. Remove the intake manifold.
- a) Disconnect the following hoses, after marking them:
- (1) Crankcase ventilation hose from intake manifold.
- (2) Air conditioner idle speed increase valve vacuum hose from intake manifold.
- (3) Manifold Absolute Pressure Sensor Vacuum Hose from Gas Filter.
- (4) Brake booster vacuum hose from intake manifold.
- b) Disconnect the two engine wiring harness protection clamps from the timing belt cover No.2 mounting bolts in the sequence shown in the figure.
- c) Disconnect the two engine wiring harness clamps from the intake manifold mounting bracket.
- d) Unscrew six bolts, two nuts and remove the intake manifold and gasket.
18. Remove the fuel manifold and injectors.
- a) Disconnect the injector connectors.
- b) Unscrew the two bolts and remove the fuel manifold together with the injectors.
Note: Be careful not to drop the injectors when removing the fuel rail.
- c) Remove the insulators and two heat-insulating bushings from the cylinder head.
- d) Remove the injectors from the fuel manifold.
- d) Remove the O-ring and seal from each injector if you will be replacing them with new ones during installation.
19. Remove the timing belt from the camshaft toothed pulley.
- a) Remove timing belt cover No.2 by unscrewing 5 bolts and remove two gaskets.
- b) Loosen the tension roller mounting bolt and push the roller to the left, being careful not to damage the belt surface, and tighten the bolt.
- c) Remove the timing belt from the pulley
- d) Cover the hole (under cover No.1) with a rag so that nothing gets in there.
20. After unscrewing the bolt, remove the camshaft toothed pulley using a special tool.
21. Remove the tension roller and spring by unscrewing the bolt.
22. Remove timing belt cover No.3 by unscrewing four bolts.
Note:
- Hold the timing belt so that the crankshaft sprocket and belt do not move.
- Be careful not to drop anything inside the timing belt cover.
- Do not allow the belt to come into contact with oil, water or dust.
23. Remove the generator bracket and the right engine lifting hook by unscrewing the three bolts.
24 Remove the oil pressure sensor.
25. Unscrew the four nuts, remove the spark plug tube seal, cylinder head cover and gasket.
Note: Arrange the spark plug tube seals in the order they were removed for proper installation to minimize the possibility of oil leakage.
26. Remove the high-voltage wire clamps, the crankcase ventilation valve and the hose from the cylinder head cover.
- a) Loosen the bolt and remove the high-voltage wire clamps (1).
- b) Remove the crankcase ventilation valve (2), hose (3) and seal (4).
- c) Remove the crankcase ventilation hose (3).
27. Remove the intake and exhaust camshafts.
Note: Since the axial clearance of the camshaft is very small, to prevent jamming and/or damage to the shaft during its removal, it is necessary to hold the shaft in a horizontal position, to do this, it is necessary to follow the removal procedure described below.
- a) Use a wrench to turn the camshaft 2-3 turns, first turn the crankshaft so that the pistons are in the middle position. Apply paint marks to the crankshaft pulley for subsequent installation.
- b) Find the timing marks on the gears and mark them with a marker.
- c) Install the camshafts in their original position and measure the thermal clearances in the valves so that they can be adjusted immediately during assembly.
27.1. Remove the exhaust camshaft.
- a) Install the intake camshaft so that the hole for the intake camshaft gear technological bolt is 10-45° before installation in B MT, as shown in the figure.
Note: In this position, the camshaft lobes of the exhaust valves of cylinders No.2 and No.4 act on the valve tappets.
- 6) Attach the exhaust camshaft auxiliary gear to the main gear with a process bolt.
Recommended process bolt:
- thread diameter - 6 mm
- thread pitch - 1.0 mm
- bolt length - 16-20 mm
Note: When removing the camshaft, ensure that this operation neutralizes the torsional force of the auxiliary gear plate washer.
- c) Unscrew the two bolts and remove the rear bearing cover.
- d) Uniformly loosen and remove the 6 bearing cap bolts No.1, No.2 and No.4 in several passes in the sequence shown in the figure.
Note: Do not remove bearing cap bolts #3 during this operation.
- d) Remove bearing caps No.1, No.2 and No.4.
- e) Loosen and remove the two bearing cap bolts No.3 one by one.
- g) Remove bearing cap N83 and exhaust camshaft
Note:
- If the camshaft does not lift straight and level, retighten the bearing cap mounting bolts #3 and perform the operations for installing the bearing caps and the dowel pin. Then perform the operations for removing the exhaust camshaft again.
- Do not use a special tool to remove the camshaft.
27.2. Remove the intake camshaft.
- a) Set the intake camshaft alignment pin to 80-115° before TDC.
Note: In this position, the camshaft lobes of the intake valves of cylinders No.1 and No.3 act on the valve tappets.
- 6) Unscrew the two bolts, remove the front bearing cover and seal.
- c) Uniformly loosen and remove the 6 bearing cap bolts No.1, No.3 and No.4 in several passes in the sequence shown in the figure.
Note: Do not remove bearing cap bolts #2 during this operation.
- d) Remove bearing caps No.1, No.3 and No.4.
- d) Loosen and remove the two bearing cap bolts #2 one by one
- e) Remove bearing cap No.2 and camshaft.
Note:
- If the camshaft does not lift straight and level, retighten the bearing cap mounting bolts #2 and perform the operations for installing the bearing caps and the dowel pin. Then perform the operations for removing the camshaft again.
- Do not use a special tool to remove the camshaft.
28. If necessary, disassemble the exhaust valve timing chain.
- a) Place the camshaft in a vice as shown in the figure.
Note: Do not damage the camshaft as it is fragile.
- b) Insert the service bolt (A) into the service hole of the auxiliary camshaft drive gear.
- c) Using a screwdriver, turn the auxiliary gear clockwise and remove the technological bolt (B).
Note: Be careful not to damage the camshaft.
- d) Remove the retaining ring using pliers.
- d) Remove:
- (1) Spring washer;
- (2) Auxiliary camshaft drive gear;
- (3) Camshaft gear spring ring.
29. Remove the cylinder head.
- a) Uniformly loosen and remove the 10 cylinder head bolts in several passes in the sequence shown in the figure.
Note: Incorrect order of loosening the bolts may result in deformation of the cylinder head or the appearance of cracks.
- 6) Remove the cylinder head from the guide pins on the cylinder block and place it on a workbench, placing wooden blocks and rags underneath.
Note: If the cylinder head is difficult to remove, you can use a powerful screwdriver by inserting it into the gas joint as shown in the figure. However, be careful not to damage the surfaces of the head and block, as well as the cylinder head gasket.
