Removal and Installation of Cylinder Head

PROCEDURE

Camshaft Drive 1 – crankshaft pulley bolt; 2 – crankshaft pulley; 3 – camshaft drive lower cover; 4 – lower cover bolt; 5 – camshaft drive belt; 6 – crankshaft gear; 7 – water pump gear; 8 – camshaft drive upper cover

Cylinder Head 1 – cylinder head gasket; 2 – cylinder head; 3 – oil seal; 4 – cover gasket; 5 – cylinder head cover; 6 – retaining plate; 7 – oil filler cap; 8 – cap gasket; 9 – valve guide; 10 – locating sleeve; 11 – cylinder head bolt

Camshaft Drive Belt Tension Adjustment 1 – water pump mounting bolt; 2 – water pump gear; 3 – camshaft drive belt; 4 – camshaft drive rear cover; 5 – camshaft gear; 6 – cylinder head; 7 – cylinder block; 8 – crankshaft pulley; 9 – ignition timing plate with timing mark; A – TDC mark on crankshaft pulley; B – TDC mark on camshaft gear; C – TDC mark on cylinder head; D – TDC mark; E – ignition advance angle mark

Cylinder Head Bolt Tightening Sequence

Engine removed from vehicle. PROCEDURE 1. Remove the generator adjusting bracket bolt from the cylinder head. 2. Remove the upper camshaft drive cover 8 (see figure Camshaft Drive). 3. Remove the cover 5 (see figure Cylinder Head) and gasket 4. 4. Remove the intake pipe and exhaust manifold. 5. Turn the crankshaft so that the No. 1 piston is at TDC on the compression stroke, with both valves closed. The mark on the camshaft gear must align with the mark on the cylinder head, as shown in the figure.

Camshaft Drive Belt Tension Adjustment. Then turn the crankshaft a quarter turn counterclockwise so that no piston is at TDC. 6. Loosen the belt tension 3. To do this, slightly loosen the three water pump mounting bolts 1 and pivot the pump toward the cylinder block. 7. Remove the belt from the camshaft gear. 8. Loosen the cylinder head bolts 11 (see figure Cylinder Head) evenly, in the reverse of the sequence shown in figure Cylinder Head Bolt Tightening Sequence. 9. Remove the cylinder head. 10. Remove the cylinder head gasket 1 (see figure Cylinder Head). 11. After inspecting and replacing damaged and worn parts, install the cylinder head in reverse order. Replace the cylinder head gasket 1 and cover gasket 5. Place the cylinder head gasket 1 on the cylinder block surface with the word "OBEN-TOP" facing up.

12. Before installing the camshaft drive belt, set the camshaft, then the crankshaft, to TDC.

13. Tighten the cylinder head bolts in the sequence shown in figure Cylinder Head Bolt Tightening Sequence, in four stages: Stage 1 40 N·m; Stage 2 60 N·m; Stage 3 tighten an additional quarter turn (90°); Stage 4 tighten an additional quarter turn (90°).

Warning: Cylinder head bolts may be retightened only on a cold engine. 14. After installing the cylinder head, check and, if necessary, adjust the ignition timing and valve clearances. Engine installed in vehicle. If it is necessary to replace or lap the valves, clean carbon from the combustion chambers, replace the cylinder head gasket, etc., the cylinder head can be removed without removing the engine from the vehicle. PROCEDURE 1. Disconnect the negative battery cable. 2. Drain the engine cooling system (see subsection 2.4.1). 3. Remove the air filter. 4. Remove the spring clamps and disconnect the muffler inlet pipe from the exhaust manifold. 5. Disconnect the high-tension leads and remove the spark plugs. 6. Disconnect all wiring, cables and hoses connected to the cylinder head. 7. Then proceed as with the engine removed from the vehicle (see above).