Withdrawal
1. Disconnect the battery from the ground.
2. Drain the coolant.
3. Disconnect from a throttle branch pipe ventilating hoses.
4. Remove the air duct by disconnecting the hoses.
5. Remove the cover from the ignition coils and from the suction manifold.
6. Disconnect the throttle and cruise control cables.
7. Decompress the fuel system (Ch. 5).
8. Disconnect the fuel lines.
9. Disconnect the crankcase ventilation hose, disconnect both vacuum hoses from the brake booster.
10. Disconnect the breather hose from the cylinder head cover, disconnect the 3 hoses of the cooling system on the throttle pipe.
11. Remove the alternator belt.
12. Jack up the engine and remove the engine side support.
13. Remove the hydraulic booster pump from its mounts, take it aside and fix it without disassembling the lines.
14. Disconnect wires and remove the generator.
15. Locate and disconnect connectors that prevent removal of the cylinder head, including connectors for engine sensors, ignition coils, and fan switches.
16. Remove all 6 ignition coils.
17. Remove the suction manifold.
18. Disconnect the connectors from the injectors and remove the fuel distributor.
19. Disconnect the vacuum hoses from the air bypass valve.
20. Remove the camshaft belt.
21. Disconnect both hoses from the radiator, disconnect the heater hoses.
22. Disconnect the exhaust pipe from the manifold, remove both exhaust manifolds.
23. Remove the thermostat housing with a branch pipe.
24. Remove the camshaft sprockets and rear belt covers.
25. Remove cylinder head covers.
26. Turn away bolts of each head of cylinders in the sequence, return shown on a photo, doing 1/3 turns at one time. Remove the cylinder heads.
Installation
27. 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 (base head height 121 mm).
28. Install a new head gasket.
29. Clean the oil nozzle and install, replacing the seal. Install new control pins.
30. Align the camshaft belt drive sprocket so that the mark on the pulley aligns with the pointer on the oil pump cover.
31. Make sure that the piston of the 1st cylinder is set to TDC.
32. Align the TDC marks on the camshaft sprockets with the pointers.
33. Install both cylinder heads.
34. Tighten the bolts in the following order (perform each tightening step simultaneously on both heads).
- 1st stage - tighten the bolts with a torque of 39 Nm,
- 2nd stage - tighten the bolts with a torque of 69 Nm,
- 2nd stage - tighten the bolts with a torque of 98.1 Nm.
35. Install suction manifolds, replacing gaskets. Tighten the bolts to 31 Nm. in a diagonal order, starting from the central part and moving to the periphery.
36. Install the exhaust pipe on the manifolds. Tighten the fastening nuts with a torque of 33 Nm.
37. Install heat shields.
38 Install the camshaft belt.
39. Adjust valve clearances.
40. Install the cylinder head covers. Tighten the bolts diagonally to 12 Nm.
41. Install the thermostat housing with the pipe.
42. Install the suction manifold, replacing the gasket.
43. Install ignition coils.
44. Install the generator and power steering pump, adjust the pump belt tension.
45. Raise the engine and install the engine side support and alternator belt tensioner bracket.
46. Install the cylinder head cover.
47. Attach the wires, hoses, cables in place. Install the rest of the removed parts.
48. Change engine oil and filter. Fill with coolant.
49. Warm up the engine, check the adjustment of the cables, adjust if necessary.
The free play of the cruise control cable should be 3.25-4.25 mm. The throttle cable must have 10-12 mm slack at the point of attachment to the throttle.