Necessary special tools and equipment
- Mot. 591-04 Angle wrench for tightening the cylinder head bolts and a pointer on a magnetic base for angled bolt tightening.
- Mot. 1202 Pliers for flexible clamps.
- Mot. 1273 Belt tension gauge.
- Mot. 1379 Device for fixing the engine on the subframe.
- Socket head Torx 12.
- Goniometer disk for angular tightening.
Tightening torques, Nm
- Crankshaft pulley bolt: 20 + 90°.
- Bolt of fastening on the engine of a forward right arm of a pendulum suspension bracket: 62.
- Mounting bolt on the body of the front right arm of the pendulum suspension: 62.
- Nut of fastening of a tension roller of a timing belt: 50.
- Wheel bolts: 90.
Removing
1. Place the vehicle on a two post lift.
2. Remove the hood, right wheel.
3. Disconnect the battery.
4. Drain the liquid from the cooling system.
5. Install Moi 1379 shims to secure the engine to the subframe.
6. Remove:
- drive belt gas distribution mechanism (see section «Drive belt gas distribution mechanism»);
- oil dipstick;
- vacuum hose of the vacuum brake booster;
- air filter;
- throttle cable;
- pipelines for supplying and returning fuel from the top cover of the timing drive.
7. Disconnect:
- wires of candles using fixture 3 built into a protective plastic casing 4;
- absorber tube, as well as hoses of the fuel vapor recovery system from the solenoid valve:
- connectors for the ignition module, injectors, idle speed controller stepper motor and throttle position potentiometer;
- idle speed controller stepper motor;
- throttle position potentiometer;
- air temperature sensor.
8. Remove the hose connecting the water pump to the heater core and disconnect the electrical harness from the heat shield on the valve cover.
9. Remove:
- mounting bolts 5 of the throttle valve bracket on the cylinder head;
- nuts for fastening 3 manifolds to the cylinder block;
- mounting bolts 4 manifolds on the valve cover;
- an assembly consisting of an intake manifold, a throttle valve block and a fuel distribution rail.
10. Remove:
- thermostat hoses;
- valve cover,
- bolts of fastening of a head of the block of cylinders;
- cylinder head.
Cleaning and checking
Attention! It is not allowed to clean the mating surfaces of aluminum parts with a tool with a sharp edge. Use Decapjoint to dissolve adhering gasket residue.
1. Apply the compound to the surface to be cleaned. Wait for about ten minutes, then remove any adhesive residue with a wooden spatula. This operation is recommended to be performed with gloves.
Attention! This operation must be carried out carefully to avoid foreign particles entering the system of channels for supplying pressurized oil to the camshaft (channels are located in the cylinder block and cylinder head).
Failure to do so may result in blockage of the rocker jets and cause rapid wear of the cams and rocker bearing surfaces.
2. Check the deformation of the mating surface. The maximum allowable flatness is 0.05 mm.
3. Check up absence of cracks of a head of the block of cylinders.
Installation
1. The cylinder head is centered using two bushings located at the rear of the engine.
Attention! To ensure proper tightening of the bolts, use a syringe to remove any remaining oil that may be in the cylinder head bolt holes.
2. Lubricate the threads and bottom of the bolt heads with engine oil.
5. Tighten the cylinder head bolts with an angle disc (see chapter «Maintenance»).
6. Align the marks on the timing belt with the marks on the toothed pulleys.
7. Install the timing belt (see section «Drive belt gas distribution mechanism»).
8. If necessary, adjust the clearances in the valve drive mechanism (see chapter «Maintenance»).
9. Install in the reverse order of removal.
Attention! Tightening the intake manifold mounting parts:
- - gradually tighten the six nuts until the manifold comes into contact with the cylinder head, then tighten the nuts to a torque of 15 Nm;
- - install the upper bolts and tighten them with a torque of 9 Nm.
10. Remove shims Mot. 1379 for fixing the engine to the subframe.
11. Fill with coolant and bleed air from the cooling system (see chapter «Maintenance»).
12. Adjust the throttle cable.