You will need: the same tools as for removing the timing belt, camshaft pulley (see «Replacing and adjusting the belt tension, replacing the tension roller of the timing drive»), cylinder head cover (see «Replacing the cylinder head cover gasket»), as well as the key «at 13», socket TORX E14, torque wrench, pliers.
1. Reduce the pressure in the supply system (see «Reducing the pressure in the power system»).
2. Disconnect the wire from the terminal «minus» battery.
3. Drain the liquid from the engine cooling system (see «Coolant replacement»).
4. Remove the timing belt from the camshaft pulley (see «Replacing and adjusting the belt tension, replacing the tension roller of the timing drive»).
5. Disconnect the downpipe from the exhaust manifold (see «Replacement of elements of system of release of the fulfilled gases»).
6. Remove the air filter (see «Removal and installation of the air filter»).
7. Having pressed the clamps, disconnect the pads of the wiring harnesses from the injectors...
8.... from the throttle position sensor...
9.... absolute pressure sensor...
10.... coolant temperature sensor...
11.... intake air temperature sensor...
12.... and idle speed controller.
13. Disconnect the block of the wiring harness of the oxygen concentration sensor...
14.... and remove the harness from the holder on the engine.
15. On the side of the engine facing the bulkhead, unscrew the nut securing the spacer to the intake pipe, unscrew the bolt of its fastening to the cylinder block...
16.... and remove the spacer.
17. Remove the engine harness from the holders on the intake pipe at the rear...
18.... and in front.
19. Having unfastened the upper holders of the engine harness in front with a screwdriver...
20....and behind...
21.... remove the harness from the front...
22.... and rear holders.
23. Remove the harness from the middle upper holder on the inlet pipe...
24....and take him aside.
25. Remove the end of the throttle cable from the ball pin of the intermediate lever...
26.... remove the cable from the hole in the bracket and take it to the side.
27. Disconnect the adsorber purge hose from the inlet pipe.
28. Disconnect the fuel line from the fuel rail (see «Removal and installation of the fuel rail»).
29. Disconnect the hose to the vacuum brake booster from the inlet pipe by squeezing the clamps of its fastening.
30. Loosen the clamps of the three hoses, squeezing their bent antennae with pliers, slide the clamps along the hoses...
31.... and disconnect the hoses from the nozzles of the thermostat and the cylinder head.
32. Remove the heater hoses from the holders on the bracket.
33. Turn out a bolt of fastening «mass» wires...
34.... and disconnect the wire.
35. Turn out a bolt of fastening of an arm of the pump of the hydraulic booster of a steering to a head of the block.
36. Remove the cylinder head cover (see «Replacing the cylinder head cover gasket»).
37. Loosen the tightening of ten cylinder head bolts in the specified order...
38.... finally unscrew the head mounting bolts, remove them...
39.... and remove the washers installed under the bolts.
Attention! Be sure to replace the block head bolts with new ones. Reuse is not allowed. Please note that the bolts are different lengths. When removing them, remember the location of the bolts and then reinstall them in their original places.
40. Remove the cylinder head assembly with the intake pipe, throttle assembly and exhaust manifold...
Note. Removing the cylinder head is more convenient with an assistant, as it is quite heavy.
41.... then remove its gasket.
42. Clean the mating surfaces of the head and block.
43. Check up a head of the block on lack of a buckling. To do this, place the ruler with an edge on the surface of the head, first in the middle along, then across, and also along the diagonals and with a feeler gauge, measure the gap between the plane of the head and the ruler. Replace the cylinder head if the clearance exceeds 0.05 mm.
44. Establish a head of the block of cylinders in sequence, return to removal, taking into account the following:
- remove oil or coolant from the threaded holes of the cylinder head bolts that got there when the head was removed;
- be sure to install a new head gasket, reuse of the gasket is not allowed;
- replace the bolts with new ones;
- lubricate the bolts with engine oil;
- tighten the bolts on a cold engine in the following order in four steps:
- I stage (pre-settlement of the gasket) - tighten the bolts to a torque of 20 Nm (2 kgf·m), then tighten by an angle of 100°±6°. Make an exposure of 3 minutes;
- Stage II - loosen bolts 1 and 2, then tighten them again with a torque of 20 Nm (2 kgf·m) and tighten by an angle of 110°±6°;
- Stage III - loosen bolts 3, 4, 5 and 6, then tighten them again with a torque of 20 Nm (2 kgf·m) and tighten by an angle of 110°±6°;
- Stage IV - loosen bolts 7, 8, 9 and 10, then tighten them again with a torque of 20 Nm (2 kgf·m) and tighten by an angle of 110°±6°.
45. Establish all removed details and knots, except for a cover of a head of the block of cylinders and the air filter, in an order, the return to removal.
46. Adjust the tension of the timing belt (see «Replacing and adjusting the belt tension, replacing the tension roller of the timing drive») and accessory drive belt (see «Checking the tension of the accessory drive belt»).
47. Check and, if necessary, adjust the clearances in the valve drive (see «Valve clearance adjustment»).
48. Install the cylinder head cover (see «Replacing the cylinder head cover gasket»).
49. Install the air filter (see «Removal and installation of the air filter»).
50. Fill with coolant (see «Coolant replacement»).