Note: For cylinder head gasket (set) catalog numbers, see 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 13 mm wrench, a TORX E14 socket head, a torque wrench, and pliers.
1. Relieve the pressure in the fuel system (see here).
2. Disconnect the negative terminal of the battery.
3. Drain the coolant (see here).
4. Remove the timing belt (see here).
5. Disconnect the intake pipe from the exhaust manifold (see here).
6. Remove the air filter housing (see here).
7. After pressing the clamps, 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 the idle speed control 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 manifold at the rear...
18. ...and in front.
19. Using a screwdriver, disconnect the upper holders of the engine wiring harness at the front...
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 intake pipe...
24. ...and take him aside.
(Data taken from the specified website LADAMAN)
25. Remove the throttle cable end from the intermediate lever ball joint...
26. ... remove the cable from the bracket hole and move it to the side.
27. Disconnect the purge hose from the canister from the intake pipe.
28. Disconnect the fuel line from the fuel rail (see here).
29. Squeeze the fastening clamps and disconnect the hose from the intake pipe to the brake booster.
30. Loosen the clamps securing the three hoses and slide them along the hoses...
31. ...and disconnect the hoses from the thermostat and cylinder head pipes.
32. Remove the heater hoses from the holders on the bracket.
33. Unscrew the bolt securing the ground wire...
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 ten cylinder head mounting bolts in the order shown 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 cylinder head mounting bolts with new ones. Their reuse is not permitted.
Please note that the bolts are of different lengths. When removing them, remember the location of the bolts and then install them in their original places. (See the bolt catalog numbers. here)
40. Remove the cylinder head assembly with the intake pipe, throttle body and exhaust manifold...
It is better to remove the cylinder 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 the cylinder head for warping. To do this, place the ruler edgewise on the surface of the head, first in the middle along, then across, and also diagonally, and use a feeler gauge to measure the gap between the surface of the head and the ruler. Replace the cylinder head if the gap is more than 0.05 mm.
44. Install the head in the reverse order of removal, taking into account the following:
- remove any oil or coolant from the threaded holes of the cylinder head mounting bolts that got there when removing the head;
- be sure to install a new cylinder head gasket, reusing the gasket is not allowed;
- replace the bolts with new ones;
- lubricate the bolts with engine oil;
The order and torques of tightening the cylinder head bolts
Tighten the bolts on a cold engine in the following four steps:
- Stage I (preliminary settling of the gasket) - tighten the bolts to a torque of 20 Nm, then turn them further at an angle of 10°±6° Wait 3 min;
- Stage II - loosen bolts 1 and 2, then tighten them again to a torque of 20 Nm and turn them further by an angle of 10°±6°;
- Stage III - loosen bolts 3-6, then tighten them again to a torque of 20 Nm and turn them further at an angle of 10°±6°;
- Stage IV - loosen bolts 7-10, then tighten them again to a torque of 20 Nm and turn them further at 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 the 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 with coolant.
For K4M engine
You will need: socket heads "10", "16", "18", TORX E14, key "13", screwdriver, lock for setting TDC, camshaft lock, torque wrench, pliers.
1. Reduce the pressure in the fuel system (see here).
2. Disconnect the negative terminal from the battery.
3. Drain the engine coolant (see here).
4. Remove the timing belt (see here).
5. Disconnect the intake pipe from the exhaust manifold (see here).
6. Remove the intake manifold receiver (see here).
7. Remove the air filter housing (see here).
8. Disconnect the wiring harness connectors from the fuel injectors...
9. ...and the fuel rail (see here).
10. Disconnect the wiring harness connectors from the throttle position sensor, coolant temperature sensor, and oxygen sensor (same as on K7M above).
11. Loosen the clamps securing the two hoses, slide them along the hoses and disconnect the hoses from the thermostat pipes...
12. ...and cylinder heads.
13. Remove the power steering pump mounting bolts and move the pump to the side (see here).
14. Remove the cylinder head cover (see here).
15. Remove the camshafts.
16. Using a TORX E14 socket head, remove ten cylinder head mounting bolts (see photo at the bottom of the section) and remove the bolts.
After unscrewing, the cylinder head mounting bolts are replaced with new ones. Their reuse is not permitted according to the regulations. Please note that the bolts are of different lengths. Remember their location (catalog numbers of bolts see here).
17. Remove the cylinder 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 the cylinder head for warping. Place a metal ruler with its edge on the surface of the head, first in the middle along, then across and diagonally, and use a feeler gauge to measure the gap between the surface of the head and the ruler. Replace the cylinder head if the gap is more than 0.05 mm.
21. Install the cylinder head in reverse order. In this case:
- 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 stages:
Cylinder head splinter bolt tightening sequence
- Stage I (preliminary settling of the gasket) - tighten the bolts to 20 Nm;
- Stage II - tighten the bolts to an angle of 240°±6°.
22. Install all removed parts in reverse order.
23. Adjust the timing belt tension (see here).
24. Fill with coolant (see here).