To remove the cylinder head, disconnect the wires from the battery terminals. Place a container under the engine to collect the coolant, open the cap of the expansion tank, disconnect the outlet hose from the radiator and drain the coolant. Disconnect the engine cooling and heater hoses from the cylinder head. Disconnect crankcase ventilation hoses. Disconnect the air line connecting the fuel dispenser to the throttle body. Disconnect the throttle cable. Disconnect fuel lines from injectors. Disconnect the wiring blocks of the sensors and other devices of the fuel injection system, including the coolant temperature sensor, starting injector, etc. Remove the front protective covers of the timing belt of the camshaft drive.
Remove the upper part of the intake manifold, disconnect the high voltage wires of the ignition system, remove the cylinder head cover. Loosen the nut securing the tension roller axle, loosen the tension of the camshaft drive belt and remove it. Remove the alternator tensioner. Working from below the vehicle, remove the bolts securing the muffler exhaust pipe flange to the exhaust manifold. Loosen the cylinder head bolts in the reverse order of tightening the bolts and remove the cylinder head.
To install, turn the crankshaft, set the pistons of the 1st and 4th cylinders to the TDC position. Install the cylinder head gasket with the surface marked «Oben» («Up») towards the plane of the cylinder head. By turning the exhaust camshaft pulley, put the mark on the pulley at the level of the upper plane of the cylinder head, pointing it towards the front of the car.
Install the cylinder head to the cylinder block. Install the cylinder head bolts, then tighten them. observing the specified order and tightening torques and tightening angles. Fit the camshaft timing belt onto the pulleys and adjust its tension. as mentioned above. Install the front camshaft belt guards. Install the upper part of the intake manifold, connect the high voltage wires. install the cylinder head cover. Connect electrical connectors. Connect fuel lines to injectors. Install air duct. Connect crankcase breather hoses. Connect the hoses of the engine cooling system and interior heater. Install the alternator tension bar. Tighten the bolts securing the muffler exhaust pipe flange to the exhaust manifold. Connect the wires to the battery.
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