Cylinder head
1. Cylinder head cover gasket (always replace); 2. Bearing sleeve; 3. Rubber bushing; 4. Cover of main bearings; 5. Rear camshaft oil seal (always replace); 6. Rear camshaft gear; 7. Back cover; 8. Hydraulic valve lifter; 9. Rotary valve mechanism; 10. Upper plate of the valve spring; 11. Valve stem seals; 12. Valve spring; 13. Valve spring support; 14. Valve; 15. Vortex chamber; 16. Valve seat; 17. Cylinder head gasket (always replace; Depending on the size of the pistons, there are gaskets of various thicknesses); 18. Places for applying sealant (before installing the cylinder head cover gasket, apply a sealing agent to these places); 19. Camshaft; 20. Front camshaft oil seal (always replace); 21. Bearing sleeve; 22. Front cover; 23. Rubber bushing; 24. Spring; 25. Front camshaft gear; 26. Side plate (for camshaft gear)
Cylinder head bolt numbering
Bolt tightening order
Removing
1. Disconnect the battery ground cable.
Attention! This erases the electronic memory, such as the radio code. Before disconnecting the battery, read the instructions in subsection 7.2.
2. Drain the coolant completely and collect it in a container.
3. Remove the muffler intake pipe.
4. Disconnect all cooling system hoses from the cylinder head.
5. Remove the air channel.
6. Unscrew the exhaust manifold heat shield.
7. Unscrew the exhaust manifold.
8. Remove the cylinder head cover with gasket.
9. Set the piston of the 1st cylinder to the TDC position.
Attention! After that, the position of the crankshaft and camshaft should not change.
10. Remove the toothed belt.
11. Loosen the cylinder head bolts in sequence in 3 passes (see fig. Cylinder head bolt numbering).
12. Loosen all bolts 1/2 turn in sequence.
13. Loosen all bolts 1 more turn.
14. Turn out all bolts.
Attention! The cylinder head may warp or burst if the bolt loosening sequence is not followed.
15. Check that all hoses and wires leading from the cylinder head to the engine and body are disconnected.
16. Remove the cylinder head with an assistant.
Attention! After removal, do not place the cylinder head on the sealing surface, otherwise fully open valves may be damaged. Place the cylinder head on 2 wooden blocks.
Installation
1. Clean the cylinder head and check for deformation.
2. Check water, oil and fuel hoses for damage and cracks, replace if necessary.
3. Check valves and valve seats for wear and damage.
4. Install the cylinder head gasket so that the holes in the cylinder block and the cylinder head gasket line up.
Attention! There are cylinder head gaskets in various thicknesses, which are indicated by 1, 2 or 3 serifs on the edge. If only the gasket is replaced, be sure to install a new gasket of the same designation. If the cylinder block, pistons, connecting rods and crankshaft have been replaced or repaired, the gasket thickness should be selected in accordance with the protrusion of the pistons (performed in the workshop).
5. Put on the cylinder head.
6. Coat the cylinder head bolts and washers with a thin coat of clean engine oil and screw in as indicated (see fig. Bolt tightening order). Make sure the beveled side of the washers is facing the bolt heads. The flat side of the washer faces the cylinder head.
7. Screw in the cylinder head bolts by hand until they fit with the collar.
8. Then tighten bolts 1 to 10 in 5 passes.
9. On each pass, the bolts must be tightened in the specified sequence.
10. Tighten bolts 1 to 10 to 40 Nm.
11. Tighten bolts 1 to 10 to 90 Nm.
12. Loosen bolts 10 to 1 completely.
13. Tighten bolts 1 to 10 to 40 Nm.
14. Tighten bolts 1 to 10 with a hard wrench in one pass by 75°.
15. This will require an angle gauge, if this device is not available, tighten the bolts 1 to 10 with a force of 90 Nm.
Attention! Bolts must be tightened with great care. Bolts must always be tightened in 5 passes. Before tightening, check the accuracy of the torque wrench. In addition, the tightening sequence must be followed exactly.
16. Install the toothed belt.
17. Install the cylinder head with a new gasket, pre-apply sealing agent to the bearing caps 1 and 5.
18. Apply sealant to the opposite locations of the cylinder head cover.
19. Lightly tighten all bolts to a maximum of 4 Nm.
Attention! If the bolts are overtightened, leaks may occur.
20. Screw the exhaust manifold with a force of 20 Nm.
21. Install the exhaust manifold heat shield.
22. Install the air duct.
23. Put all the hoses of the cooling system on the cylinder head and secure with clamps.
24. Install the muffler downpipe.
25. Connect the battery ground cable.
26. Fill with coolant.