Withdrawal
1. Disconnect the battery from the ground.
2. Remove the cylinder head cover and camshaft belt top cover.
3. Set the piston of the 1st cylinder to the TDC of the compression stroke by turning the crankshaft until the marks are aligned.
4. Drain the coolant.
5. Drain the engine oil.
6. Disconnect throttle and cruise control cables (if provided). Deformation or excessive bending of the cable during removal is not allowed
7. Remove the air duct, air filter.
8. Designate and disconnect hoses of ventilation of a crankcase and recirculation system.
9. Decompress the fuel system.
10. Disconnect the fuel lines at the pressure regulator.
11. Disconnect the vacuum hoses next to the fuel return line.
12. Disconnect all vacuum hoses from a collector.
13. Remove the hydraulic booster hose from the suspension cap.
14. Disconnect from a collector the tire on weight.
15. Remove all wiring harnesses from the cylinder head cover.
16. Remove the power steering pump drive belt.
17. Disconnect the wires at the bottom of the suction manifold.
18. Label and disconnect engine wiring connectors (including connectors for injectors, sensors, idle air valve, ignition coils)
19. Disconnect wires from the distributor of ignition. Remove the ignition distributor.
20. Disconnect the radiator and heater hoses from the cylinder head.
21. Install a jack under the engine and hang the engine a little. Remove the through bolt and remove the engine side mount.
22. Remove the cylinder head cover.
23. Remove the camshaft belt after removing the covers.
24. Remove the rear camshaft belt cover and camshaft sprocket.
25. Lift the car, disconnect from a collector a forward exhaust pipe and lower the car.
26. Remove the exhaust manifold and shield.
27. Remove the thermostat housing by unscrewing the bolts and turning the housing.
28. Remove the fuel distributor and nozzles.
29. Turn away bolts and remove an equalizing chamber with a throttle branch pipe.
30. Remove the suction manifold.
31. Turn away bolts of a head of cylinders in diagonal sequence, having begun from the periphery and being displaced to the center, doing 1/3 turns at one time. Remove the cylinder head.
Installation
32. Clear a head and a demountable plane of the block of cylinders. Check the deformation of the planes, which should not exceed 0.15 mm. If the deformation exceeds 0.15 mm, grind the head. When grinding, it is allowed to reduce the height of the head by no more than 0.20 mm (basic head height 100 mm).
33. Install a new head gasket.
34. Make sure that the piston of the 1st cylinder is set to TDC.
35. Clean the oil nozzle and install, replacing the seal. Install new control pins.
36. Wrap bolts of fastening of a soaking-up collector to an arm, without tightening.
37. Install the camshaft with the UP mark facing up.
38. Establish a head of cylinders, be convinced that pins have come into openings of a head. On engines 1996-97. lubricate the bolts and tighten by hand. Tighten the bolts in the following order.
Tighten the bolts diagonally in three stages: tighten the bolts to 39 Nm, then retighten to 69 Nm. And finally tighten with a torque of 98.1 Nm.
On 1998 engines, lubricate the bolts and tighten in the following order.
- 1st stage - tighten the bolts with a torque of 39 Nm,
- 2nd stage - apply marks on the bolt heads and the surface of the cylinder head in accordance with the photo,
- 3rd stage - tighten the bolts by 90°relative to the marks on the cylinder head,
- 4th stage - tighten the bolts by another 90°, tighten the new bolts by another 90°relative to the position in the 4th stage of tightening.
39. Install the suction manifold, surge chamber and throttle connection.
40. Install the nozzles on the pressure regulator, install the regulator on the suction manifold, replacing all gaskets and seals.
41. Install the exhaust manifold by lifting the car.
Marks on the cylinder head bolts, which are tightened when tightening: 1. Bolt head; 2. Cylinder head
42. Install the rear camshaft belt cover. Install the key and sprocket on the camshaft, tighten the sprocket bolt to 37 Nm.
43. Make sure that the UP mark on the camshaft sprocket is facing up, and the orientation of the crankshaft and camshaft pulleys corresponds to the position of the piston of the 1st cylinder at TDC of the compression stroke.
44. Install the camshaft and balancer shaft belts.
45. Install the lower camshaft belt cover and tighten the bolts to 12 Nm.
46. Install a new seal around the adjusting nut. Do not loosen the nut.
47. Put on the crankshaft pulley, tighten the bolt with a torque of 245 Nm.
48. Install the engine side support. Tighten the engine mounting bolts to a torque of 55 Nm, tighten the support through bolt nut to a torque of 65 Nm.
49. Adjust valve clearances.
50. Install the camshaft belt top cover. Tighten the bolt on the suction manifold side with a torque of 12 Nm, on the exhaust manifold side - with a torque of 10 Nm.
51. After adjusting the valves, check the tightening of the crankshaft pulley bolt, tighten if necessary with a torque of 245 Nm.
52. Install the cylinder head cover, tighten the cover nuts clockwise with a torque of 10 Nm.
53. Install the thermostat housing, replacing the gasket. Connect the bypass hoses of the cooling system.
54. Next, the assembly is performed in the reverse order of disassembly. Attach hoses, wires and cables. Adjust belt tension. Adjust throttle and cruise control cables. Fill the engine with oil and fluid. When finished, start the engine, check the ignition setting, adjust if necessary.