- Reduced engine power.
- Low coolant level, white exhaust smoke when the engine is hot.
- Coolant in engine oil. The oil level does not decrease, but rather increases. Gray oil in the engine, foam on the oil dipstick. Oil liquefaction.
- Engine oil in the coolant, decreasing oil.
- Lack of compression in two adjacent cylinders.
Withdrawal
Disconnect the ground wire from the battery.
Remove engine compartment hood (see section «Removal and installation of a cowl of a motor compartment»).
Remove toothed belt (see section «Removal and installation of a gear belt»).
Open the throttle actuator cover.
Detach throttle cable -1- by opening clip in direction of arrow.
With automatic transmission: Detach cable -2-.
Unscrew bolts -3- and lay cables with holder to one side.
Disconnect connector -4- for idle speed adjuster and vacuum hoses -5- and -6-.
Loosen the clamps and remove the air intake hose.
Turn to the left and unplug connector -1- for air mass meter.
Unplug connector -2- for fuel tank valves 4.
Disconnect connector -1- for injectors and connector for throttle valve switch.
Detach heating hose -3-.
Disconnect fuel hoses -4- and close with appropriate plugs.
Unscrew the fuel hose holders.
Loosen bolts -5- for battery support.
Remove the radiator hose.
Raise the car.
Remove front exhaust pipe from exhaust manifold (see section «Exhaust system»).
Drain the coolant from the engine by unscrewing the drain plug on the engine block under the exhaust manifold. After draining the liquid, immediately wrap and tighten the drain plug.
Disconnect the ventilation hose.
Unscrew the cylinder head cover.
Pull out the camshaft cover -1-
Loosen the cylinder head bolts 1/2 turn in sequence 10-1. To loosen the cylinder head bolts, an E12 Torx wrench is required.
You can also install a torque wrench on one of the bolts along the engine block, measure out a 93°angle with a protractor, and make a chalk mark on the cylinder head.
Remove cylinder head.
Attention: After removal, do not place the cylinder head on the contact surface, as this may damage the open valves. Therefore, put the cylinder head on two wooden spacers.
Installation
Before installing, clean the cylinder head and cylinder block from the remnants of the old seal. Do not allow seal residues to enter cylinder bores.
Close the cylinder bores with rags.
Measure the flatness of the cylinder head and engine block with a steel ruler in the longitudinal and transverse directions and, if necessary, mill (work must be done at a service station).
Check the cylinder head for cracks and the cylinder sliding surfaces for scratches.
Thoroughly clean the holes for the cylinder head bolts from oil and other objects.
Attention: There must be no oil in the recesses, otherwise the bolts will not fully tighten the cylinder head, despite the fact. that they will be tightened to the required torque. In addition, it can break the motor block.
Be sure to replace the cylinder head gasket.
Apply a new gasket without sealing compound so that it does not block the holes. Inscription «TOR» should be facing up, and the inscription «FRONT» - to the toothed belt.
Replace O-ring for hole -1- in engine block.
Before installing the cylinder head, check that the camshaft is at top dead center (see section «Removal and installation of a gear belt»).
Install the cylinder head.
Be sure to replace and lightly lubricate the cylinder head bolts with engine oil. Install only new bolts.
Caution: Be very careful when tightening the cylinder head bolts. Before tightening the bolts, check the accuracy of the torque wrench. In addition, a protractor, such as the HAZET 6690, is required to tighten the cylinder head bolts.
You can also install a torque wrench on one of the bolts along the engine block, measure out a 93°angle with a protractor, and make a chalk mark on the cylinder head.
The cylinder head bolts are tightened in 3 passes. On each pass, the tightening is performed in the sequence 1-10.
1st pass: tighten with a torque wrench to a torque of 30 Nm.
2nd pass: 90°hard wrench tightening.
3rd pass: 90°hard wrench tightening.
Install toothed belt (see section «Removal and installation of a gear belt»).
Insert the camshaft cover.
Install the cylinder head cover. Tighten the bolts crosswise to 9 Nm.
Connect the crankcase breather hose.
Secure front exhaust pipe with new self-locking nuts with a new gasket. Tightening torque: preliminary - 30 nm; final - 50 nm. Bolts are pre-coated with high-temperature paste (see section «Exhaust system»).
Tighten the manifold support bolts.
Connect all hoses and secure with clamps.
Connect electrical wires.
Screw on fuel pipe holders.
Screw the cable holders, connect the cables.
Install the throttle lever cover.
Connect ground wire to battery.
Fill the cooling system with coolant (see section «Coolant replacement»).
Check engine oil level. If the cylinder head was removed due to a defective gasket, it is recommended to change the engine oil with the replacement of the oil filter, since coolant could have entered the oil.
Install engine compartment hood (see section «Removal and installation of a cowl of a motor compartment»).
Note: The cylinder head bolts do not need to be tightened after 1000 km.