To replace the cylinder head gasket you will need: a torque wrench, 13, 17, 19 mm wrenches, 10, 13, 17 mm socket heads, a 10 mm Allen key, and a screwdriver.
1. Remove the decorative engine cover (see "Removal and installation the decorative engine cover").
2. Set the piston of the 1st cylinder to the TDC position of the compression stroke (see "Setting the piston of the first cylinder to the TDC position of the compression stroke").
3. Reduce the pressure in the engine fuel system if the work is performed immediately after driving (see "Reduced fuel pressure in the engine fuel system").
4. Disconnect the wire from the negative terminal of the battery.
5. Drain the coolant (see "Replacing the coolant").
6. Remove the air filter (see "Removal and installation the air filter").
7. Disconnect the heating hoses, small branch of the crankcase ventilation system, purge hose of the adsorber, air supply pipe, connectors of the wiring harnesses of the throttle position sensor and idle speed control valve from the throttle assembly (see "Removal and installation the throttle assembly").
8. Disconnect the high-voltage wire ends from the spark plugs.
9. Disconnect the wires from the low oil pressure warning light sensor.
10. Disconnect the wires from the coolant temperature sensor (coolant temperature sensor) engine management systems and phase sensor.
11. Remove the cylinder head cover (see "Replacing the cylinder head cover gasket").
12. Remove the front camshaft drive cover (see "Setting the piston of the first cylinder to the TDC position of the compression stroke").
13. Loosen the camshaft sprocket mounting bolt while holding the camshaft from turning (this can be done by inserting a large screwdriver or pry bar into the holes in the pulley hub).
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14. Remove the timing belt (see "Timing Belt Replacement (camshaft drive) and tension roller").
15. Completely unscrew the camshaft pulley mounting bolt and remove the pulley.
16. Remove the rear cover of the camshaft drive (see "Replacing the water pump").
17. Loosen the clamps and disconnect the five cooling system hoses from the thermostat pipes.
18. Unscrew the nut securing the ground wire tip and disconnect the wire.
19. Disconnect the wire from the coolant temperature gauge sensor.
20. Disconnect the injector wire harness connector and disconnect the fuel supply hose from the fuel rail pipe (see "Removal and installation the fuel rail").
21. Disconnect the hose to the brake booster from the intake module fitting by loosening the clamp that secures it.
22. Disconnect the upper ends of the spacers from the intake pipe (see "Replacing the catalytic converter").
23. Disconnect the oxygen concentration sensor wire harness connectors and remove their wire holders from the steering gear heat shield openings (see "Replacing the catalytic converter").
24. Disconnect the additional muffler inlet pipe from the catalytic converter flange and disconnect the catalytic converter support bracket from the cylinder block (see "Replacing the catalytic converter").
25. Loosen the ten cylinder head bolts in the order shown...
26. ...then completely unscrew the cylinder head mounting bolts and remove them together with the washers.
27. Remove the cylinder head. Cylinder head bolts tend to stretch out with repeated use. Bolts, the length of which (excluding head height) exceeds 135.5 mm, replace with new ones. Before installing the cylinder head, lubricate the bolts with a thin layer of engine oil.
28. Remove the cylinder head gasket.
29. Clean the mating surfaces of the cylinder head and cylinder block (they must be dry and clean) and remove oil from the threaded holes in the block under the cylinder head mounting bolts.
30. Check the presence of two installation bushings in the sockets of the outer holes of the cylinder block for the head mounting bolts. If, when removing the cylinder head, the bushings remain in the head or come out of the block sockets, press them into the block until they stop.
31. Install a new head gasket on the cylinder block (the cylinder head gasket must be dry and clean) by mounting bushings. In this case, the hole for the passage of oil in the gasket (with copper edging) should be located between the 3rd and 4th cylinders.
32. Install the head on the cylinder block, after making sure that the crankshaft and camshaft are in the TDC position (both valves of the 1st cylinder must be closed). Tighten the cylinder head bolts in the following four steps in the following sequence:
- 1 - torque 20 Nm (2 kgf•m);
- 2 - torque 69.4-85.7 N·m (7.1-8.7 kgf·m);
- 3 - tighten the bolts by 90°;
- 4 - finally tighten the bolts by 90°.
33. Install the removed parts onto the cylinder head and connect the hoses and wires to it in the reverse order of removal. Install the camshaft pulley with the protruding part of the hub facing the engine. Check and, if necessary, adjust the valve clearances (see "Adjusting valve clearances"). Adjust the tension of the camshaft drive belt (see "Timing Belt Tension Adjustment (camshaft drive)").