Removal the cylinder head. 1 - generator and coolant pump drive belt; 2 - generator; 3 - generator lock bolt (M3=18 Nm); 4 - generator mounting bolt (M3=58 Nm); 5 - coolant pump drive pulley; 6 - cylinder block with cylinder head assembly; 7 - Coolant inlet pipe No.2 gasket; 8 - oil dipstick sealing ring; 9 - oil dipstick assembly with guide; 10 - fastening bolt of inlet pipe No.2 of coolant (M3=9.3 Nm); 11 - nut for fastening the inlet pipe No.2 of the coolant (M3=15 Nm); 12 - Coolant inlet pipe No.2; 13 - Hoses of the forced crankcase ventilation system; 14 - intake manifold support support mounting bolt (M3=39 Nm); 115 - intake manifold support support mounting bolt (M3=19 Nm); 16 - intake manifold support stand; 17 - air bypass tube; 18 - intake manifold; 19 - intake manifold mounting bolt (M3=19 Nm); 20 - intake manifold gasket; 21 - Air intake chamber cover gasket; 22 - air intake chamber cover mounting bolt; 23 - air intake chamber cover; 24 - gasket between the flange of the air intake chamber inlet pipe and the support post of the air intake chamber; 25 - gasket under the throttle body; 26 - engine transport hook (eye); 27 - throttle body; 28 - throttle body mounting bolt (M3=22 Nm); 29 - eye mounting nut (M3=28 Nm); 30 - bolt for fastening the air intake chamber support stand (M3=28 Nm); 31 - Air intake chamber support post; 32 - fuel manifold mounting bolt (M3=15 Nm); 33 - fuel manifold assembly with injectors; 34 - heat-insulating sleeve of the injector manifold; 35 - injector insulator; 36 - Engine wiring; 37 - bolt for fastening the combined ignition unit (contactless ignition system unit) M3=20 Nm; 38 - combined ignition unit (ignition distributor sensor with ignition coil or contactless ignition system unit) with high voltage wires; 39 - sealing ring of the ignition distributor sensor housing; 40 - coolant inlet pipe and coolant supply unit to the cylinder head; 41 - bolt for fastening the coolant supply unit to the cylinder head (M3=20 Nm); 42 - coolant outlet pipe from cylinder head; 43 - coolant outlet pipe mounting bolt (M3=15 Nm); 44 - exhaust manifold parts for serial engines with catalytic converter of exhaust gases; 45 - exhaust manifold heat shield; 46 - exhaust manifold; 47 - exhaust manifold gasket; 48 - exhaust manifold mounting nut (M3=34 Nm); 49 - exhaust manifold support bracket; 50 - exhaust manifold support bracket mounting bolt (M3=39 Nm); 51 - exhaust manifold support bracket mounting bolt (M3=59 Nm); 52 - exhaust manifold parts for other engines; 53 - Upper heat-insulating casing of the exhaust manifold; 54 - exhaust manifold; 55 - lower heat-insulating casing of the exhaust manifold; 56 - exhaust manifold mounting nut (M3=34 Nm); 57 - exhaust manifold support stand; 58 - exhaust manifold support support mounting bolts (M3=39 Nm); 59 - Air intake chamber and intake manifold parts for lean-burn engine; 60 - air intake chamber cover; 61 - Air intake chamber cover gasket; 62 - fuel manifold assembly with injectors; 63 - common fuel line mounting bolt (collector) injectors (M3=9.3 Nm); 64 - distance sleeve (spacer) of the injector bolt; 65 - injector isolator; 66 - intake manifold; 67 - intake manifold mounting bolt (M3=19 Nm); 68 - intake manifold gasket; 69 - spacer (housing) of additional flaps; 70 - gasket of the housing of additional controlled flaps.
Note: This engine has an intake manifold with 8 separate intake ports connecting the air intake chamber (resonator) to each intake valve, with servo-controlled additional flaps installed in the spacer channels directly in front of the intake valves, partially blocking the channels at low loads.
Removal the cylinder head (continuation).
1 - timing belt; 2 - rubber stopper; 3 - timing belt cover No.2; 4 - timing belt cover fastening bolt No.2 (M3=7.4 Nm); 5 - timing belt cover No.3; 6 - timing belt cover fastening bolt No.3 (M3=7.4 Nm); 7 - segment plug (detail; installed with preliminary priming); 8 - bolt for fastening the exhaust camshaft drive pulley (M3=59 Nm); 9 - exhaust camshaft drive pulley; 10 - oil seal; 11 - exhaust camshaft; 12 - retaining (clamping) ring; 13 - wave spring washer; 14 - auxiliary gear of the intake camshaft; 15 - leaf spring of intake camshaft gear; 16 - intake camshaft; 17 - camshaft bearing cap; 18 - camshaft bearing cover mounting bolt (M3=13 Nm); 19 - Spark plug protective tube gasket; 20 - timing mechanism cover (cylinder heads); 21 - sealing washer; 22 - cap nut; 23 - Cylinder head cover gasket; 24 - adjusting washer (for adjusting the thermal clearance in the valves); 25 - valve tappet; 26 - crackers; 27 - valve spring plate (holder); 28 - valve spring; 29 - valve stem seal; 30 - valve spring support washer (seat); 31 - valve guide; 32 - valve; 33 - spark plug; 34 - cylinder head mounting bolt (M3=29 Nm); then sequentially turn each bolt by 90°; then turn each bolt 90° again; 35 - cylinder head; 36 - cylinder head gasket; 37 - Generator mounting bracket; 38 - generator bracket mounting bolt (M3=26 Nm); 39 - engine transport hook (eye); 40 - eye mounting bolt (M3=28 Nm).
Removal the cylinder head
1. Disconnect the cable from the negative battery terminal.
2. Drain the coolant.
3. Remove the alternator and coolant pump drive belt (see the subsection "Removing the timing belt" of the section "Timing belt").
4 Disconnect the engine wiring, having first disconnected or removed: the generator connector (1), the generator wiring (2), the emergency oil pressure sensor connector (3), two wiring clamps (4).
Then remove the engine wiring harness protector and disconnect the wiring from the cylinder head.
5. Remove the generator by unscrewing its mounting bolt, nut and adjusting bolt.
6. Remove the exhaust manifold.
4A-FE (serial version)
- a) Unscrew 3 bolts, 2 nuts and remove the upper heat-shielding casing.
- b) After unscrewing 3 bolts, remove the exhaust manifold support stand.
- c) After unscrewing 5 nuts, remove the exhaust manifold and gasket.
4A-FE (except for the serial version)
- a) Unscrew 4 bolts and remove the upper heat shield.
- b) After unscrewing 2 bolts, remove the exhaust manifold support stand.
- c) After unscrewing 5 nuts, remove the exhaust manifold and gasket.
- d) After unscrewing 3 bolts, remove the lower heat shield from the exhaust manifold.
(7A-FE)
- a) Unscrew 4 bolts and remove the upper heat shield.
- b) Unscrew the bolt securing the support stand to the exhaust manifold.
- c) After unscrewing 5 nuts, remove the exhaust manifold and gasket.
- d) After unscrewing 2 bolts, remove the exhaust manifold support stand.
7. Remove the coolant drain pipe by unscrewing the two mounting bolts.
8. Remove the combined ignition unit (ignition sensor-distributor with ignition coil (contactless ignition system unit), having previously removed the high-voltage wires (holding them only by the rubber covers) and unscrewing the 2 nuts securing the combined ignition unit.
9. Remove the housing of the coolant supply pipes to the cylinder head.
- a) Disconnect the coolant temperature sensor connector, coolant bypass hoses and the vacuum hose of the bimetallic solenoid valve of the fuel vapor recovery system.
- b) Unscrew the bolt and 2 nuts and remove the coolant supply pipe housing.
10. Remove the throttle body (see the chapter " Fuel injection system (petrol engines)").
11. Remove the engine transport hook (eye), having first unscrewed the bolt (or bolts) and disconnected the air bypass tube and the fuel supply tube. Then, having unscrewed the bolt and nut, remove the eye, the air intake chamber support stand (resonator) and gasket.
7A-FE.
4A-FE (serial version).
4A-FE (lean Bum system option).
12. Remove the intake manifold support stand by unscrewing the 3 bolts.
13. Remove the air bypass tube, having first disconnected the fuel return line tube and unscrewed the bolt and nut.
14. Disconnect the engine wiring from the intake manifold by unscrewing the bolt and 2 nuts.
15. Remove the air intake chamber cover:
Disconnect 2 hoses of the system: forced crankcase ventilation and vacuum transfer hose.
Using a 6mm Allen key, remove the 3 bolts, 2 nuts and the air intake chamber cover and gasket.
16. Disconnect the fuel return line tube from the fuel differential pressure regulator.
17. Disconnect the fuel supply pipe from the common fuel line (collector) injectors by unscrewing and removing the bypass bolt with gaskets.
18. Disconnect the injector connectors.
19. Remove the fuel manifold assembly with injectors.
- a) Unscrew 2 bolts (for engines with Lean Bum system - 3 bolts) and remove the injector manifold together with the injectors.
4A-FE (serial version) and 7A-FE.
4A-FE variant with Lean Bum system.
Note: Do not drop the injectors while removing the manifold.
- b) Remove 4 insulators and 2 spacers (for engines with Lean Burn system - 3 spacers) from the intake manifold.
- c) Remove 4 injectors from the common fuel line (collector) injectors.
- d) Remove the sealing ring and rubber bushing from each injector.
20. Unscrew 7 bolts, 2 nuts and the intake manifold together with the gasket (for engines with Lean Bum system - with two gaskets and air bypass valve).
21. Remove the oil level indicator from the guide, unscrew the mounting bolt, and remove the entire unit (pointer with guide) and remove the sealing ring gasket.
22. Remove coolant supply pipe No.2.
- a) Unscrew the 2 nuts securing the pipe to the head.
- b) Disconnect the supply pipe from the coolant pump.
23. Remove the spark plugs using a special key
24. Remove the cylinder head cover with gasket by unscrewing the 4 cap nuts and removing the seals.
25. Remove timing belt protective covers No.3 and No.2.
26. Set the piston of the 1st cylinder to TDC at the end of the compression stroke.
- a) Turn the crankshaft pulley and align the groove on the pulley with the synchronizing mark "O" on the protective cover No.1 of the timing belt.
- b) Make sure that the small hole in the exhaust camshaft drive toothed pulley aligns with the timing mark on the 1st camshaft bearing cap.
Otherwise, rotate the crankshaft one more revolution (360°).
27. Remove the timing belt from the camshaft toothed pulley.
- a) Apply timing marks to the toothed pulley and the timing belt, as well as a mounting mark to the belt where it exits the timing belt protective cover No.1.
- b) Remove the rubber plug from timing belt cover No.1.
- c) Loosen the timing belt tension roller mounting bolt, move the tension roller to the left until it stops and temporarily tighten the tension roller bolt again.
- d) Remove the toothed belt from the camshaft drive toothed pulley.
Notes:
- Hold the belt in such a way as to prevent the belt from changing engagement with the crankshaft toothed pulley.
- Do not allow any objects to enter the timing belt guard.
- Do not allow the belt to come into contact with oil, water or dirt.
28. Remove the engine transport hook (eye) and the generator mounting bracket.
29. Remove the timing belt pulley from the camshaft, having first secured the camshaft with an adjustable wrench and unscrewed the pulley bolt.
30. 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 removal, it is necessary to hold the shaft in a horizontal position, to do this, it is necessary to follow the removal procedure below
- A. Remove the intake camshaft.
- a) Turn the intake camshaft so that the auxiliary gear installation hole is in the position shown in the figure.
In this case, the camshaft cams of the intake valves evenly press on the valve tappets of the 1st and 3rd cylinders.
- b) Unscrew 2 bolts and remove the cover of the 1st camshaft bearing.
- c) Secure the intake camshaft auxiliary gear to the drive gear with the installation bolt.
- The recommended mounting bolt is M6x1, 16-20 mm long.
Note: When removing the camshaft, make sure that this operation neutralizes the torsional force of the auxiliary gear torsion spring.
- d) Loosen the intake camshaft bearing cap bolts evenly in several passes in the sequence shown in the figure and remove the bolts.
- d) Remove the inlet camshaft bearing caps and then the camshaft itself.
Note:
- Do not apply significant force or attempt to use a screwdriver or any other object as a lever
- If the camshaft does not come off, install the 3rd bearing cap, tighten it, and then loosen the bolts while pulling the shaft out by the gear.
- B. Remove the exhaust camshaft.
- a) Turn the exhaust camshaft with an adjustable wrench until the alignment pin is in the position shown in the figure.
In this case, the camshaft cams of the exhaust valves press evenly on the valve tappets of the 1st and 3rd cylinders.
- b) Unscrew 2 bolts and remove the cover of the 1st camshaft bearing.
- c) Loosen the exhaust camshaft bearing cap bolts evenly in several passes in the sequence shown in the figure and remove the bolts.
- d) Remove the exhaust camshaft bearing caps and then the camshaft itself.
Note:
- Do not apply significant force or attempt to use a screwdriver or any other object as a lever.
- If the camshaft does not come off, install the 3rd bearing cap, tighten it, and then loosen the bolts while pulling the shaft out by the gear.
31. Disassemble the intake camshaft.
- a) Clamp the camshaft with its hexagonal part in a vice.
Note: Be careful not to damage the camshaft.
- b) Insert the technological bolts (A) and (B) into the technological holes of the auxiliary gear of the camshaft.
- c) Using a screwdriver, turn the camshaft auxiliary gear clockwise and hit the service bolt (C).
Caution: Do not damage the camshaft.
- d) Remove the retaining ring using pliers.
- d) Remove: spring washer (1), camshaft auxiliary gear (2) and gear spring (3).
32. Remove the segment (semicircular) plug
33. Remove the cylinder head.
- a) Using a suitable tool, loosen and remove the cylinder head bolts evenly and in several passes in the sequence shown in the illustration, then remove the 10 washers.
Caution: Warping or cracking of the cylinder head may be a result of incorrect loosening of the cylinder head mounting bolts.
- b) Lift the cylinder head off the dowel pins and place it on a workbench with some wooden blocks underneath.
Note: If the cylinder head is difficult to remove, you can use a 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.
