Removal
The operations are common for all vehicle configurations.
Place the vehicle on a two-post lift, apply the parking brake, turn off the ignition and disconnect the ground wire from the battery.
For cars with K4M engine
Remove the right front wheel.
Remove the right side mudguard.
Remove the accessory drive belt.
Remove the crankshaft pulley.
Remove the right engine mount.
Remove the timing belt.
Remove the intake silencer.
Remove the air filter housing.
Remove the throttle body.
Remove the intake manifold.
Remove the camshaft seals from the timing drive side.
Remove the ignition coils.
Disconnect the crankcase ventilation hose 1, Figure 9-1, from the oil separator 2.
Unscrew the eight mounting bolts (replaceable head 8, extension, ratchet).
Separate oil separator 2 from cylinder head cover 4 (flat head screwdriver).
Figure 9-1 - Removing the oil separator and lifting eye: 1 - crankcase ventilation hose; 2 - oil separator; 3 - lifting eye; 4 - cylinder head cover
Loosen bolts 1, Figure 9-2, securing the cylinder head cover (8 mm socket, extension, ratchet wrench).
Figure 9-2 - Removing the cylinder head cover of the K4M engine: 1 - cylinder head cover mounting bolts
Separate the cylinder head cover by pulling it upwards and tapping the protrusions with a bronze drift (technological punch).
Remove the cylinder head cover.
For cars with K7M engine
Remove housing 1, Figure 9-3, of the air filter.
Figure 9-3 - Removing the cylinder head cover of the K7M engine: 1 - air filter housing; 2 - ignition module; 3 - cylinder head cover; 4 - pipe of the gasoline vapor recovery system
Remove ignition module 2.
Disconnect pipe 4 of the gasoline vapor recovery system from the holder on the cylinder head cover.
Disconnect pipe 1, Figure 9-4, and crankcase ventilation hose 2 from the cylinder head cover.
Figure 9-4 - Disconnecting the crankcase ventilation hose: 1 - crankcase ventilation tube; 2 - crankcase ventilation hose; 3 - cylinder head cover
Loosen bolts 1, Figure 9-4, securing the cylinder head cover (8 mm socket, extension, ratchet wrench).
Figure 9-5 - Removing the cylinder head cover: 1 - cylinder head cover mounting bolt
Remove the cylinder head cover.
Remove the cylinder head cover gasket.
Installation
For cars with K4M engine
On using sealant instead of gasket: Assembling motors using sealants is easier, faster and cheaper. There is no need to purchase additional product items. Moreover, some types of sealants have advantages over rubber if used correctly.
There are several types of sealants. The most famous is silicone, which is capable of filling cavities up to 6 millimeters, and retains its properties and elasticity for a long time during operation.
[Full article on the website ladaman.ru]
In addition, silicone withstands high pressure well, which allows it to be used in high-performance engines. The only subtle point is that the mating surfaces must be thoroughly degreased before application. One of the most popular in industrial assembly is anaerobic sealant. It can only be applied to relatively flat surfaces, but it is convenient to work with. There are a number of other compounds, such as synthetic and polyurethane sealants, but they are more of a universal type.
Clean the cylinder head and head cover from any remaining sealant.
Degrease the mating surfaces of the cylinder head and cylinder head cover (brush, white spirit).
Apply MASTIXO sealant with a paint roller, Fig. 9-6 (paint roller, sealant MASTIXO part number 77 11 428 232).
Figure 9-6 - Applying sealant to the cylinder head cover of the K4M engine
Remove the sealant from the working surfaces of the bearings in the cylinder head cover (rag).
Install the cylinder head cover.
Figure 9-7 - Tightening order of the cylinder head cover bolts for the K4M engine: 1...24 - cylinder head cover mounting bolts
Install and tighten bolts 1...24, Fig. 9-7, in the specified order, securing the cylinder head cover in several stages (replaceable head 8, extension, torque wrench):
- Stage 1 - bolts 22, 23, 20 and 13 with a tightening torque of 8 Nm (0.8 kgf·m);
- Stage 2 - bolts 1 - 12, 14 - 19, 21 and 24 with a tightening torque of 15 N·m (1.5 kgf·m);
- Step 3 - Loosen bolts 22, 23, 20 and 13;
Install lifting eye 3, Figure 9-1, of the engine from the flywheel side onto the cylinder head cover. Tightening torque of the mounting bolt 11 N·m (1.1 kgf·m) (replaceable head 16, torque wrench).
Clean oil separator 2 from sealant residues.
Degrease the mating surfaces of the cylinder head cover and oil separator (brush, white spirit).
Apply MASTIXO sealant to the oil separator using a paint roller in accordance with Figure 9-8 (paint roller, sealant MASTIXO part number 77 11 428 232).
Figure 9-8 - Applying sealant to the oil separator of the K4M engine
Install the oil separator.
Install and tighten bolts 1...8, Figure 9-9, of the oil separator mounting in the order shown. Tightening torque of oil separator mounting bolts 15 Nm (1.5 kgf·m) (replaceable head 8, extension, torque wrench):
Figure 9-9 - Tightening order of the K4M engine oil separator mounting bolts: 1...8 - oil separator mounting bolts
Connect the crankcase ventilation hose 1, Figure 9-1, to the oil separator 2. Install the ignition coils.
Install the intake manifold.
Install the throttle body.
Install the air filter housing.
Install the intake noise muffler.
Install the timing belt.
Install the right engine mount.
Install the crankshaft pulley.
Install the accessory drive belt.
Install the right side mudguard.
Install the right front wheel.
For cars with K7M engine
Clean the sealing surface of the cylinder head cover.
Attention: The cylinder head cover gasket must be replaced. Install the cylinder head cover with a new gasket.
Figure 9-10 - Tightening order of the cylinder head cover bolts for the K7M engine: 1...8 - cylinder head cover mounting bolts
Install and tighten in the specified order bolts 1...8, Fig. 9-10, securing the cylinder head cover in two stages (replaceable head 8, extension, torque wrench):
- 1st stage - tightening torque 2 Nm (0.2 kgf·m);
- 2nd stage - tightening torque of 10 Nm (1.0 kgf·m).
Connect tube 1, Figure 9-4, and crankcase ventilation hose 2 to cylinder head cover 3.
Connect pipe 4, Figure 9-3, of the gasoline vapor recovery system to the holder on the cylinder head cover.
Install ignition module 2.
Install air filter housing 1.
The operations are common for all vehicle configurations.
Connect the ground wire terminal to the battery.