Contents: Removal ↡ Installation ↡
Cylinder head installation details
3, 9 - Bolts; 4 - Bushing; 5 - Air supply tube; 6a - Bypass valve; 6 - Intake manifold bracket; 6a - Oil level indicator guide tube; 8c - Branch pipe; 8b - Sealing ring; 10 - Cylinder head; 11 - Gasket; 12 - Guide pins; 41 - Finger
Removal
1. Drain the coolant and disconnect the cooling pipes from the cylinder head. 2. Bring the piston of the first cylinder to the TDC position at the end of the compression stroke.
3. Remove the front upper cover. 4. Mark the position of the camshaft sprockets relative to the timing chain (arrows).
5. Remove the guide lever pin or sliding lever pin using a puller.
6. Unscrew the camshaft adjuster fittings.
7. Remove the timing chain from the camshaft sprockets.
8. Disconnect the engine wiring. To do this, loosen all the tie straps and disconnect all the wiring connectors.
9. Disconnect the cruise control rod. 10. Disconnect the wiring connector (X25/17) and the wiring connector (X16/1x1) from the electronic accelerator drive, press the pawl and turn it 90°.
11. Disconnect the vacuum tubes from the intake manifold.
12. Loosen the bolts securing the exhaust system to the exhaust manifold flange. 13. Disconnect the check valve tube from the exhaust air mixing tube (arrow) and loosen the bracket (1).
14. Unscrew the oil level indicator guide pipe bracket and the intake manifold bracket.
15. Disconnect the tube (43) from the bracket (17) on the cylinder block.
16. Slowly open the fuel filler cap to relieve pressure in the fuel system. Unscrew the fuel lines.
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17. On models with AT: unscrew the oil level indicator guide pipe from the rear of the cylinder head.
18. Disconnect the drive cable (30) from the control lever (9). To do this, squeeze the plastic clamp (28).
19. Loosen the clamping bands securing the cooling system pipes to the cooling system pump. Remove the return pipe. 20. Loosen the cylinder head mounting bolts in the reverse order to that shown in the illustration. The engine must be cold.
21. Remove bearing caps Nos. 9 and 13. Install lifting eyes and remove the cylinder head from the engine.
22. Wipe the contact surfaces of the cylinder head and cylinder block. Replace the cylinder head gasket.
Installation
Installation is performed in the reverse order of removal. The tightening order of the cylinder head bolts is shown in the illustration.
