2. Front cylinder head. Disconnect the guide tube 1 of the oil dipstick (see illustration).
4.2 Disconnect the guide tube 1 of the oil dipstick
3. Unscrew bolts 2, which secure the intake pipe 5 to the exhaust manifold on the front cylinder head (see illustration 4.2).
4. Unscrew the two bolts 3 that secure the generator support bracket (see illustration).
4.4 Unscrew the two bolts 3 that secure the generator support bracket
5. Remove the heat reflector shield 4 (see illustration 4.4).
6. Disconnect the intake pipes 5 and 6 from the exhaust manifold of the rear cylinder head by unscrewing the mounting bolts (see illustration 4.2).
7. Unscrew the lambda probe 7 from the connecting pipe 8 of the catalytic converter of the exhaust system of the front cylinder head, disconnect both inlet pipes, as well as the catalytic converter (see illustration).
4.7 Unscrew the lambda probe 7 from the connecting pipe 8 of the exhaust system of the front cylinder head of the catalytic converter and disconnect both inlet pipes
8. Disconnect the oil filter and remove the oil cooler 9 without disconnecting the oil lines from it (see illustration 4.7).
9. Unscrew the lambda probe from the connecting pipe of the catalytic converter 10 of the exhaust system of the rear cylinder head and disconnect the catalytic converter (see illustration).
4.9 Unscrew the lambda probe from the connecting pipe of the catalytic converter 10 of the exhaust system of the rear cylinder head and disconnect the catalytic converter
10. Disconnect hose 11 and bracket 12 from the front cylinder head (see illustration).
4.10 Disconnect hose 11 and bracket 12 from the front cylinder head
11. Remove battery 13 and its tray (see illustration 4.10).
12. Unscrew the mounting bolts and move the engine control unit 14 to the side (see illustration 4.10).
13. Unscrew the mounting bolts and remove the power steering pump and the power steering reservoir.
14. Unscrew the mounting bolts and move the air conditioner compressor to the side without disconnecting the hoses or refrigerant circulation lines from it.
Attention! All work related to opening the refrigerant circulation system should be entrusted to a specialized workshop.
15. Remove the intake manifold 15 and pipeline 16 from the rear cylinder head by unscrewing the mounting bolts (see arrows in the illustration).
4.15 Remove the intake manifold 15 and pipeline 16 from the rear cylinder head by unscrewing the mounting bolts (see arrows)
16. Remove the cover from the front cylinder head.
17. Release the tension of the balance shaft drive chain by compressing the tensioner spring with a suitable tool, such as 0164-F, which is used in specialist workshops, see the relevant chapter.
18. Unscrew bolt 17 and sprocket mounting bolt 18 and remove sprockets 18 and 19 together with the balance shaft drive chain (see illustration).
4.18 Unscrew bolt 17 and sprocket mounting bolt 18 and remove sprockets 18 and 19 together with the balance shaft drive chain
4 - device for loosening the tension of the balance shaft chain
19. Turn the crankshaft in the direction of engine travel until the hole on the drive shaft sprocket aligns with the hole on the rear cover of the timing mechanism and fix the drive shaft by inserting the thrust roller 20 into the holes (see illustration 4.18).
20. Remove tool 4 for loosening the balance shaft chain tension, balance shaft 21, chain tensioner 22 and tensioner spring 23 (see illustration 4.18).
21. Remove balancer 25 and take out key 24 (see illustration 4.18).
22. Install special plate 5a, securing it with two bolts 26, tightening them by hand, and then fix the chain on the camshaft sprocket with stop 5b and plate 5c (see illustration). After this, tighten bolts 26.
4.22 Install special plate 5a, securing it with two bolts 26, and then fix the chain on the camshaft sprocket with stop 56 and plate 5c
23. Disconnect the upper hose from the thermostat housing.
24. Unscrew bolts 27 with which the protective cover of the timing drive is attached to the cylinder head (see illustration).
4.24 Unscrew bolts 27 with which the protective cover of the timing drive is attached to the cylinder head
25. Remove cover 28, gasket 28 of the ignition distributor and remove runner 30 (see illustration)
4.25 Remove cover 28, gasket 28 of the ignition distributor and remove runner 30
26. Remove gasket 31, flange 32 and housing 33 of the ignition distributor (see illustration 4.25).
27. Unscrew the front cylinder head mounting bolts, acting in the specified sequence (see illustration).
4.27 Sequence of unscrewing the cylinder head bolts
28. Remove stop 35, which prevents axial runout of the camshaft, by unscrewing bolt 34 (see illustration). After removing the stop, bolt 34 must be screwed in again.
4.28 Remove stop 35, which prevents axial runout of the camshaft, by unscrewing bolt 34
29. Remove sprocket 36 from the camshaft together with the chain (see illustration 4.28)
Attention! To remove the rear cylinder head, it is necessary to dismantle the right engine mount support.
30. Unscrew bolt 37 of the right engine support bracket (see illustration).
4.30 Unscrew bolt 37 of the right engine support bracket
31. Place a garage jack under the engine, placing a wooden block on its rod, and raise the right side of the engine as much as possible to remove the right suspension mount.
32. Remove the right engine support 40 by disconnecting brackets 39 and 40 (see illustration 4.30).
33. Remove the cover from the rear cylinder head if it has not been removed previously.
34. Unscrew bolts 41, which secure the protective cover of the timing mechanism to the cylinder head, and also remove plug 42, which closes the bolt securing the camshaft sprocket (see illustration).
4.34 Unscrew bolts 41, which secure the protective cover of the timing mechanism to the cylinder head, and also remove plug 42
35. Unscrew the threaded pin 43 using two M9x125 nuts (see illustration 4.34).
36. Secure the chain to the rear cylinder head camshaft sprocket using a special device consisting of plate 2a, which is secured with bolts 43, bolt 2b and plate 2c (see illustration).
4.36 Secure the chain to the rear cylinder head camshaft sprocket using a special tool consisting of plate 2a, bolt 2b and plate 2c
37. Unscrew the bolts securing the rear head to the cylinder block, following the sequence shown (see illustration 4.27).
38. Remove stop 45, which prevents axial runout of the camshaft, by unscrewing bolt 44 (see illustration). After removing the stop, bolt 34 must be screwed in again.
4.38 Remove stop 45, which prevents axial runout of the camshaft, by unscrewing bolt 44
39. Remove the sprocket together with the chain from the camshaft by unscrewing bolt 46 (see illustration 4.38). It is recommended to screw bolt 46 into the hole on the shaft after removing the sprocket
40. Loosen the fit of the heads on the cylinder blocks, and then remove the heads using special levers [9], as well as the sealing gaskets (see illustration).
4.40 Loosen the fit of the heads on the cylinder blocks, and then remove the heads using special levers [9]
41. Remove, if necessary, the bearing housings, rocker shafts, tappets, camshafts, and valves from both heads.
4.41 Secure the cylinder liners with special clamps 6a
Attention! It is recommended to fix the cylinder liners on the blocks with special clamps 6a. screw in the 6B bolts to prevent the shell casings from escaping (see illustration).
42. Remove the bushings 49 from the cylinder block, with which the head is centered on the block. To remove the bushings, use a special tool 1, for example, 0134L (see illustration).
4.42 Remove bushings 49 from the cylinder block, with the help of which the head is centered on the block
43. Clean the mating surfaces of the cylinder heads and blocks, as well as the threads of the holes for the head mounting bolts.
44. Check the cylinder head for warpage or distortion (see illustration). Check the curvature using a steel standard ruler and a measuring template at several points. The permissible LX deformation C should not exceed 0.05 mm.
4.44 Check the cylinder head for distortion
Attention. Modification of cylinder heads is not permitted.
45. Check the piston protrusion. The piston protrusion should be within 0.05-0.12 mm. The permissible difference in the protrusion of two adjacent cylinders should not exceed 0.04 mm.