Withdrawal
1. Disconnect the cable from the negative battery terminal.
2. Set cylinder No. 1 to TDC by turning the crankshaft.
3. Drain the coolant from the cooling system. Use a clean container; close it with a lid when full and wipe up any spills immediately.
4. Reduce fuel system pressure using the appropriate procedure.
5. Remove fuel supply and return hose.
6. Remove the vacuum hose, breather hose and air intake.
7. Remove the bypass hose from the cylinder head.
8. Remove the carbon filter hose from the throttle body.
9. Remove the brake booster vacuum hose from the intake manifold. On vehicles with automatic transmission, remove the vacuum hose clamp.
10. Remove the cruise control vacuum hose.
11. Disconnect the throttle cable from the throttle body. On vehicles with automatic transmission, remove the throttle control cable from the throttle body.
Be careful not to bend the cable when removing. Do not use pliers to remove the cable from the hitch. Always replace the bent cable with a new one.
12. Disconnect 2 connectors from distributor and wires from spark plugs. Mark the location of the distributor and remove it from the cylinder head.
13. Disconnect 2 connectors from the emission control box, and remove the box. Do not disconnect emission hoses.
14. Remove the connector and clip from the alternator, then remove the engine harness from the valve cover.
15. Disconnect the engine harness connectors, then remove the harness clips from the cylinder head and intake manifold.
16. Remove the upper radiator hose and heater inlet hose from the cylinder head, then remove the heater outlet pipe bracket bolt from the intake manifold.
17. Remove the thermostat assembly from the intake manifold.
18. Disconnect the connector and vacuum hose, then remove the cruise control drive. Do not disconnect the cable; move the actuator outside of the work area with the cable attached.
19. Remove the mounting bolts and drive belt from the power steering pump, then, without disconnecting the hoses, move the pump away from the mounting bracket. Secure the pump outside the work area.
20. Raise and secure the vehicle.
21. Remove the front wheels.
22. Remove the mudguard.
23. Remove the intake manifold bracket bolts.
24. Remove the exhaust manifold and exhaust manifold insulation.
25. Remove intake manifold.
26. Remove the valve cover and engine ground wire.
27. Remove the engine side mount, then remove the upper drive belt cover.
28. Mark Rotation (cyclic shift) drive belt if it is to be used again. Loosen the camshaft belt adjusting bolt, and then loosen the belt.
29. Remove the camshaft drive belt from the camshaft pulley.
30. Remove the cylinder head bolts, then remove the cylinder head.
To prevent deformation, loosen the bolts 1/3 of a turn in sequence. Repeat the sequence until all bolts are loosened.
For installation:
31. Installation is carried out in the reverse order of the removal procedure. Pay attention to the following procedures, it will help the installation.
32. Make sure that the entire cylinder head and gasket surface are clean. Check the cylinder head for deformation. If the deformation is less than 0.05mm, cylinder head surface treatment is not required. The maximum limit - 0.2mm - is based on a cylinder head height of 99.95mm.
33. Always use a new cylinder head gasket.
34. Label "UP" on the camshaft pulley should be at the top.
35. Make sure cylinder number 1 is at TDC.
36. Cylinder head dowel pins and oil jet must be properly installed.
37. Install the bolts that secure the intake manifold to the mounting bracket, but do not tighten them.
38. Install the camshaft.
39. Tighten the cylinder head bolts sequentially in 3 steps:
- Step 1 - 40 Nm.
- Step 2 - 70 Nm.
- Step 3 - 108 Nm.
40. Install the intake manifold, and tighten the nuts in a criss-cross pattern in 2-3 steps, starting with the inner nuts. The final tightening torque must be 22 Nm. Always use a new intake manifold gasket.
41. Install the heat insulator to the cylinder head and block.
42. Install the exhaust manifold, and tighten the nuts in a criss-cross pattern in 2-3 steps starting with the inner nut. The final tightening torque must be 32 Nm. Always use a new exhaust manifold gasket.
43. Install the exhaust manifold mounting bracket, then install the exhaust pipe, bracket and upper casing.