Note. cylinder head gasket part numbers (kits) cm. Here (K7M) and Here (K4M)
For K7M engine
You will need: the same tools as for removing the timing belt and cylinder head cover, as well as a wrench «at 13», socket TORX E14, torque wrench, pliers.
1. Relieve pressure in the fuel system (see here).
2. Disconnect the terminal «minus» battery.
3. Drain the coolant (see here).
4. Remove the timing belt (see here).
5. Disconnect the downpipe from the exhaust manifold (see here).
6. Remove the air filter housing (see here).
7. Having pressed the latches, disconnect the fuel injector wiring connectors...
8. remove the throttle position sensor connector...
9.. absolute pressure sensor connector...
10. coolant temperature sensor connector...
11. Intake air temperature sensor connector...
12.... and an idle speed controller connector.
13. Disconnect the oxygen concentration sensor connector...
14.... and remove the wiring from the holder on the engine.
15. From the rear of the engine, unscrew the two nuts securing the spacer - to the intake pipe and to the cylinder block...
16.... and remove the spacer.
17. Remove the engine wiring harness from the holders on the intake pipe at the rear...
18.... and in front.
19. Having disconnected the upper holders of the engine wiring harness from the front with a screwdriver...
20....and behind...
21.... remove the harness from the front...
22.... and rear holders.
23. Remove the harness from the middle upper holder on the inlet pipe...
24....and take him aside.
25. Remove the end of the throttle cable from the ball pin of the intermediate lever...
26.... remove the cable from the hole in the bracket and take it to the side.
27. Disconnect the adsorber purge hose from the inlet pipe.
28. Disconnect the fuel line from the fuel rail (see here).
29. Squeezing the fasteners, disconnect the hose to the vacuum brake booster from the intake pipe.
30. Loosen the three hose clamps and slide them along the hoses...
31.... and disconnect the hoses from the nozzles of the thermostat and cylinder head.
32. Remove the heater hoses from the holders on the bracket.
33. Turn out a bolt of fastening «mass» wires...
34.... and disconnect the wire.
35. Remove the bolt securing the power steering pump to the cylinder head.
36. Remove the cylinder head cover (see here).
37. Loosen the tightening of ten cylinder head mounting bolts in the order indicated in the photo...
38.... finally unscrew the head mounting bolts, remove them...
39.... and remove the washers installed under the bolts.
Be sure to replace the block head bolts with new ones. Their reuse is not allowed.
Please note that the bolts are different lengths. When removing them, remember the location of the bolts and then reinstall them in their original places. (See bolt part numbers. here)
40. Remove the cylinder head assembly with intake pipe, throttle and exhaust manifold...
It is better to remove the block head with two people, as it is quite heavy.
41.... then remove its gasket.
42. Clean the mating surfaces of the head and block.
43. Check up a head of the block on lack of a buckling. To do this, place the ruler with an edge on the surface of the head, first in the middle along, then across, and also along the diagonals and with a feeler gauge, measure the gap between the surface of the head and the ruler. Replace the cylinder head if the clearance is more than 0.05 mm.
44. Install the head in the reverse order of removal, considering the following:
- remove oil or coolant from the threaded holes of the cylinder head mounting bolts that got there when the head was removed;
- be sure to install a new cylinder head gasket, reuse of the gasket is not allowed;
- replace the bolts with new ones;
- lubricate the bolts with engine oil;
The order and tightening torques of the cylinder head bolts
Tighten the bolts on a cold engine in the following order in four steps:
- I stage (pre-settlement of the gasket) - tighten the bolts to a torque of 20 Nm, after which tighten by an angle of 10°±6°Wait 3 minutes;
- Stage II - loosen bolts 1 and 2, then tighten them again with a torque of 20 Nm and tighten by an angle of 10°±6°;
- Stage III - loosen bolts 3-6, then tighten them again with a torque of 20 Nm and tighten by an angle of 10°±6°;
- Stage IV - loosen bolts 7-10, then tighten them again with a torque of 20 Nm and tighten by an angle of 10°±6°.
45. Install all removed parts and assemblies, except for the cylinder head cover and air filter housing, in the reverse order of removal.
46. Adjust timing belt tension (see here).
47. Check and, if necessary, adjust the valve clearances of the K7M engine (see here).
48. Install the cylinder head cover (see here).
49. Install the air filter housing.
50. Fill in coolant.
For K4M engine
You will need: socket heads «on 10», «at 16», «at 18», TORX E14, key «at 13», a screwdriver, a clamp for setting the TDC, a clamp for camshafts, a torque wrench, pliers.
1. Reduce the pressure in the supply system (see here).
2. Disconnect «minus» from the battery.
3. Drain engine coolant (see here).
4. Remove the timing belt (see here).
5. Disconnect the downpipe from the exhaust manifold (see here).
6. Remove the intake pipe receiver (see here).
7. Remove the air filter housing (see here).
8. Disconnect the wiring harness pads from the fuel injectors...
9....and fuel rail (see here).
10. Disconnect the harness pads from the throttle position, coolant temperature and control oxygen concentration sensors (similar to K7M above).
11. Loosen the two hose clamps, slide them along the hoses and disconnect the hoses from the thermostat nozzles...
12.... and cylinder heads.
13. Turn out bolts of fastening of the pump of the power steering and take the pump aside (see here).
14. Remove the cylinder head cover (see here).
15. Remove camshafts.
16. Turn out the socket head TORX E14 ten cylinder head bolts (see photo at the bottom of the section) and remove the bolts.
The cylinder head bolts after unscrewing are replaced with new ones. Their repeated use is not allowed according to the regulations. Please note that the bolts are of different lengths. Remember their location (bolt part numbers see here).
17. Remove the block head assembly with the exhaust manifold and intake pipe.
It is better to remove the cylinder head with an assistant, as it is quite heavy.
18. Remove the cylinder head gasket.
19. Clean the mating surfaces of the head and block.
20. Check up a head of the block on lack of a buckling. Place a metal ruler with an edge on the surface of the head, first in the middle along, then across and diagonally and with a feeler gauge measure the gap between the surface of the head and the ruler. Replace the cylinder head if the clearance is more than 0.05mm.
21. Install the cylinder head in reverse order. Wherein:
- remove oil, coolant and any contaminants from the threaded wells that got there when removing the head;
- lubricate the new bolts with engine oil;
- tighten the bolts in the order shown in two steps:
Tightening order for the cylinder head sprinkling bolts
- I stage (pre-settlement of the gasket) - tighten the bolts to 20 Nm;
- Stage II - tighten the bolts by an angle of 240°±6°.
22. Reinstall all removed parts in reverse order.
23. Adjust timing belt tension (see here).
24. Fill with coolant (see here).