Attention! On 2.1 liter engines, due to limited access to the engine compartment, the engine must be removed to remove the cylinder head.
Cylinder head bolt tightening sequence
Removing
1. Disconnect the negative terminal from the battery.
2. Drain the coolant from the cooling system.
3. Remove the intake and exhaust manifolds. Alternatively, remove the intake manifold, unscrew the exhaust manifold mounting and disconnect it from the head. In this case, the exhaust manifold can remain in place along with the turbocharger.
4. Remove the intake and exhaust manifolds. Alternatively, remove the intake manifold, unscrew the exhaust manifold mounting and disconnect it from the head. In this case, the exhaust manifold can remain in place along with the turbocharger.
5. Fix the manifold with turbocharger properly. At the same time, do not allow the tube supplying oil to the turbocharger to be deformed.
6. Disconnect and remove the fuel return hoses from the fuel injectors.
7. Disconnect the fuel supply lines from the fuel injectors and high pressure fuel pump and remove the lines.
8. Unscrew the fastening nut and remove the glow plug power cable.
9. Remove the coolant hose from the rear left end of the cylinder head.
10. Disconnect the small coolant hose from the front end of the cylinder head at the toothed belt side.
11. Remove the fuel return hose from the hangers on the cylinder head and move to the side.
12. Remove the accelerator cable from the high pressure fuel pump.
13. Remove the fuel filter/thermostat housing.
14. Unscrew the nut or coolant hose suspension bracket and move the suspension to the end of the cylinder head.
15. Remove the camshaft pulley.
16. Remove the timing belt tensioner and right engine mount.
17. Remove the toothed belt guide roller.
18. Unscrew the bolt securing the engine front plate to the high pressure fuel pump mounting bracket.
19. Unscrew the nut and bolt of the alternator and high pressure fuel pump mounting and remove the engine front plate.
20. Gradually unscrew the cylinder head bolts in the reverse order shown in fig. The sequence of tightening the cylinder head bolts.
21. Remove bolts with washers.
22. To separate the head from the cylinder block, install two steel rods bent at right angles into the bolt holes and, pressing them up and down, separate the head from the cylinder block. Do not separate the head from the cylinder block by inserting a lever between the mating surfaces, as this can damage the gasket and mating surfaces on the cylinder head and block.
23. Remove the cylinder head and gasket.
Installation
1. Turn the crankshaft clockwise until all pistons are in the middle of the piston stroke.
2. Install the required gasket on the notched cylinder block on the flywheel side. Check that the guide pin is in place.
3. Install the head to the cylinder block.
4. Treat the threads of the bolts and base of the bolt heads with Molykote G Rapid Plus.
5. Install the bolts with washers in the head and screw them in.
6. Gradually and sequentially tighten the bolts to the required torque (stage 1; see fig. Cylinder head bolt tightening sequence).
7. Retighten the bolts to the required torque (stage 2).
8. Tighten the bolts to the required angle. Further installation is carried out in the reverse order of removal.