Removing
Place the car on a lift.
Disconnect the battery.
Drain the coolant from the system.
Attention. Install plugs on the air manifold inlet.
Auxiliary equipment:
1 - tube with a tip for the Schrader 0141-T1 valve;
2 - a set of plugs for quick-detachable pipeline fittings 1520.
Release the vacuum tube from the clamps (in the zone «A») and fuse box (6).
Remove the protection under the engine, deflector (7), air intake resonator (8), air inlet (4).
Turn away bolts (1) And (3).
Remove the air filter cover (2), decorative battery cover (5) and rechargeable battery.
Release the electrical harnesses from the latches, laid at the battery tray.
Remove the battery tray.
Remove filter element (9) and remove the fasteners (10) engine cover (in the zone «b»).
Remove the decorative engine cover (11).
Turn away bolts (12) and remove the intermediate support (13) and air filter housing (14).
Disconnect the power wiring harness (in the zone «d»), connector (in the zone «e») and ignition coil wiring harness (in the zone «With»).
Unfasten and move the electrical wiring harness (15).
Remove coils (16) and spark plugs.
Release the vacuum tube from the clamps (in the zone «g»).
Disconnect and move aside the tube of the vacuum system (17) (in the zone «f»).
Disconnect the following components:
- exhaust camshaft position sensor electrical connector (in the zone «h»);
- intake camshaft position sensor electrical connector (in the zone «j»);
- power supply connector for controlled thermostat in the zone «k»);
- coolant temperature sensor connector (in the zone «l»);
- oil pressure sensor connector (in the zone «m»).
Raise and move aside the nozzle (18) engine wiring harness (in the direction of the arrow).
Disconnect the following components:
- coolant hose (entrance to the heat exchanger) (in the zone «n»);
- coolant hose (exit from the heat exchanger) (in the zone «R»);
- coolant hose (exit from the radiator) (in the zone «q»);
- coolant hose (entrance to the radiator) (in the zone «r»).
Remove the mount (19) coolant outlet block/intermediate pipe.
Turn away bolts (21).
Disconnect and remove the beneficial coolant block (22) from intermediate tube (20).
Attention. Relieve fuel pressure by connecting the end of the tool (1) to the SHRADER valve. Collect escaping fuel in a container (connection of the device in the zone «s»).
Remove the following components:
- fuel injectors;
- intake air distributor
- exhaust system catalytic converter manifold;
- timing chain.
Raise the engine with a lifting eye (23).
Install a block of wood under the oil pan.
Remove the dipstick (25).
Turn away bolts (24) And (26) and remove the engine mounts (27) And (28).
Release the fuel pipes from the clamps (in zones «t» And «u»).
Turn away bolts (29) And (30).
Unclip the power cable harness (in the zone «v»).
Remove the right intermediate engine mount (31).
Disconnect the power supply connector (solenoid valve) (32) (in the zone «w»).
Attention. Do not disassemble or repair units (33). Any damage or failure of these parts will require replacement of the head assembly.
First remove the cylinder head bolts (in sequence from 1 to 3), then unscrew the remaining bolts in sequence from 4 to 13. Remove the cylinder head and gasket.
Installation
Clean the mating surfaces of the head and gasket (do not use cutting and abrasive tools and fixtures).
Attention. The surfaces to be joined must not show signs of impact or cracks.
Replace seals regularly.
Check the flatness of the cylinder head surface (±0.05 maximum).
Install the head with camshafts and crankshaft in sequence in the locked position with the locking tools inserted into place (see chapter «Adjustment of the gas distribution mechanism»).
Make sure you have centering bushings (34) And (35).
Install a new gasket (36) (engine mark in the zone «X») and cylinder head.
Attention. When installing the cylinder head, use new bolts and washers.
Reinstall the cylinder head bolts, after lubricating their threads with a compound «MOLYKOTE G RAPID PLUS E3».
Install and tighten the cylinder head bolts (in reverse order).
Disconnect the electrovalve power connector (32) (in the zone «w»).
Reinstall the right intermediate engine mount (31).
Fasten the power wiring harness (in the zone «V»).
Reinstall the bolts (29) And (30).
Install the timing chain, exhaust catalytic converter manifold and intake air distributor.
Install fuel injectors.
Fasten the fuel pipes (in zones «t» And «u»).
Install the engine mounts (27) And (28), bolts (24) And (26) and oil dipstick (25).
Raise the engine with a lifting eye (23).
Remove the insert under the engine oil sump.
Replace the following parts:
- gaskets (37, 38) on the coolant outlet housing (22);
- bleed bolt (39);
- sealing gasket (42);
- coolant temperature sensor (40);
- retainer (41).
Install the coolant outlet assembly (22) and connect the intermediate hose (20).
Install Mount (19) coolant outlet block/intermediate pipe.
Mounts (21) tighten to 8 Nm.
Connect the cooling system hoses.
Install the rest of the parts in reverse order.
Connect the battery.
Fill and bleed air from the engine cooling system.