Removing
- Disconnect the wire from the negative battery terminal.
- Reduce the pressure in the fuel system.
- Turn out bolts, disconnect a fuel hose of a high pressure and remove an annular sealing lining.
- Loosen the clamp and disconnect the fuel return hose.
- Turn out bolts and remove a casing of the engine.
- Drain the coolant from the cooling system.
- Remove the plug and drain the engine oil from the engine.
- Disconnect the electrical connectors from the crankshaft position sensor, knock sensor, boost pressure sensor, EGR solenoid valve, ignition coil, injectors, canister purge solenoid valve, throttle position sensor, throttle control servo, misfire detection sensor, camshaft position sensor shaft, coolant temperature sensor, coolant temperature indicator sensor and front oxygen concentration sensor (pic. 3.52).
Pic. 3.52. 4G13 engine cylinder head: 1 - connector of the crankshaft position sensor; 2 - knock sensor connector; 3 - boost pressure sensor connector; 4 - connector for the exhaust gas recirculation solenoid valve; 5 - ignition coil connector; 6 - injector connectors; 7 - connector for the solenoid valve for cleaning the adsorber, 8 - connector for the throttle position sensor, damper; 9- throttle control servo connector; 10- connector for the misfire detection sensor; 11 - camshaft position sensor connector; 12 - coolant temperature sensor connector; 13 - coolant temperature indicator sensor connector; 14 - connector of the front oxygen concentration sensor; 15 - intake exhaust pipe; 16 - gasket of the intake exhaust pipe; 17 - guide tube of the engine oil level indicator; 18 - sealing ring; 19 - upper front casing of the toothed belt; 20 - camshaft pulley; 21 - cylinder head bolt, 49 Nm + loosen + 20 Nm + 90°+ 90°; 22 - cylinder head assembly; 23 - cylinder head gasket
- Turn out a bolt and disconnect a wire of connection of the block of cylinders of the engine with «weight».
- Turn out bolts and remove a cover of a head of cylinders.
- Remove the intake manifold.
- Turn out a bolt and remove a bypass tube of the engine cooling system.
- Loosen the nuts and disconnect the exhaust pipe from the exhaust manifold and remove the exhaust pipe gasket.
- Turn out a bolt and remove a directing tube of the index of level of engine oil together with a sealing ring.
- Turn out bolts and remove the top forward casing of a gear belt.
- Remove the timing belt drive timing.
- For the pulley mounting bolt, turn the crankshaft clockwise until the alignment mark on the camshaft pulley aligns with the corresponding mark, while the piston of the 1st cylinder will be set to TDC on the compression stroke (rice. 3.48).
- Fasten the toothed belt to the camshaft pulley with soft wire or band clamps, which will prevent the belt from moving relative to the camshaft pulley (rice. 3.49).
- Using special tools MD998719 or MD998754 and MB990767, block the camshaft pulley from turning and remove the pulley mounting bolt (see fig. 3.20). Remove the pulley with the toothed belt attached to it from the camshaft.
Warning. Do not turn the crankshaft after removing the pulley from the camshaft.
- Special tool in 2 or 3 passes in the sequence shown on figure 3.32, loosen and remove the cylinder head bolts. When removing the cylinder head bolts, be careful not to damage or deform the spark plug guide tubes as they are not replaceable.
- Carefully remove the cylinder head.
- Remove the cylinder head gasket.
- Cover the engine cylinders with a clean, lint-free cloth.
Installation
- Installation is carried out in the reverse order of removal, taking into account the following.
- Degrease the attached surfaces of the block and cylinder head.
- When installing, check that all holes on the gasket and cylinder head match.
- Install the gasket and cylinder head to the cylinder block.
- Check up a condition of bolts of fastening of a head, cylinders and especially their carving. Measure the length of each bolt without washer from the underside of the bolt head to the end of the bolt. If the bolt length (Ah, fig. 3.33) less than 103.2 mm, they can be reused. If any bolt is longer than specified, replace all bolts in the kit.
- Install washers on the cylinder head under the head mounting bolts, rounded side up, as shown in Figure 3.33.
- Lubricate the top surface of the washer and bolt threads with engine oil before installing.
- Tighten the cylinder head bolts in several stages in the sequence shown in figure 3.34.
Steps for tightening the cylinder head bolts:
- step 1: tighten to 49 Nm
- Step 2: Completely loosen all bolts in the reverse order shown on figure 3.34
- step 3: tighten to 20 Nm
- Step 4: Tighten the bolts by 90°. Apply paint marks on the bolt heads and cylinder head (rice. 3.35)
- Step 5: Tighten the bolts an additional 90°. The marks on the bolts and the cylinder head must be in line (rice. 3.35)
Warnings!
- (1) Always turn the bolt to a strict 90°angle. Otherwise, the cylinder head bolt may be loosened (the reliability of the gas connection will not be ensured).
- (2) If the bolt is turned more than 90°, completely loosen it and repeat all tightening operations.
- Install the camshaft pulley and secure with a bolt, tightening it to the required torque. Using special tools MB990767 and MD998719 or MD998713, block the camshaft pulley from turning and tighten the pulley mounting bolt to 88 Nm (see fig. 3.20).
- Install and bolt the cylinder head cover.
- Install the timing belt drive of the gas distribution mechanism.
- When installing the high pressure fuel hose, lubricate the O-ring with a small amount of clean engine oil (rice. 3.36).
Warning. It is not allowed to get oil into the fuel line.
- Slightly turning the fuel hose flange to the right or left, carefully insert it into the fuel line so as not to damage the O-ring. After installation, check that the hose turns smoothly in the fuel line.
- If the hose flange sticks when turning, the cause may be a damaged O-ring. Detach the flange (complete with hose) from the fuel line and check the gasket for damage, then reinsert it and check for smooth turning.
- Install the high pressure fuel hose bolts and tighten to 8.8 Nm.
- Install the cylinder head cover and secure with bolts, tightening them to the required torque.
- Install the engine oil level gauge guide tube with a new O-ring and secure with the bolt.
- Install the power steering pump and bracket.
- Install the exhaust pipe flange to the exhaust manifold and secure with nuts, tightening them to the required torque.
- Install the intake manifold.
- Fill the engine with the required amount of recommended engine oil.
- Pour coolant into the cooling system.
- Connect the wire to the negative battery terminal.
- Start the engine and check for leaks.