1.
Drain the coolant and disconnect the upper radiator hose.
Drain the coolant and disconnect the upper radiator hose.
Remove the breather hose (between the air cleaner and the rocker cover).
Remove the air-intake hose.
Remove the vacuum hose, fuel hose and coolant hose.
Remove the cables from the spark plugs. The cables should be removed by holding the boot portion.
Remove the ignition coil.
Remove the surge tank stay.
Remove the intake manifold.
Remove the heat protector and exhaust manifold assembly.
Remove the coolant pump pulley and the crankshaft pulley.
Remove the timing belt cover.
Move the timing belt tensioner pulley toward the coolant pump and temporarily secure it.
Remove the timing belt.
Remove the rocker cover.
Remove the cylinder head assembly. The cylinder head bolts should be removed using Cylinder Head Bolt Wrench, in the sequence as shown in the illustration.
Remove the gasket pieces from the cylinder block top surface and cylinder head bottom surface.
Make sure that the gasket pieces do not fall in to the engine.
Check the cylinder head for cracks, damage and coolant leakage.
Remove scale, sealing compound and carbon deposits completely. After cleaning oil passages, apply compressed aor to make certain that the passages are not clogged.
Check the cylinder head surface for flatness using a straight edge in the direction of A, B, ...as shown.
If flatness exceeds service limit in any direction, replace the cylinder head, or lightly machine the cylinder head surface.
Cylinder head flatness
Standard value
1.3 L : Less than 0.03 mm (0.012 in.)
1.1 L : Less tha 0.05 mm (0.002 in.)
Limit
1.3 L : 0.08 mm (0.0031 in.)
1.1 L : 0.1 mm (0.004 in.)
Clean all gasket surfaces of the cylinder block and the cylinder head.
Install a new cylinder head gasket into the cylinder head assembly. Do not apply sealant to the gasket and do not reuse the old cylinder head gasket.
Install the cylinder head bolts. Starting at top center. tighten all cylinder head bolts in sequence as shown in illustration, using the Cylinder Head Bolt Wrench. Repeat the procedure, retightening all cylinder head bolt to the specified torque.
Tightening torque
1.3 L : 23~27NM (230~270kg.cm, 17~20lb.ft)+60°+60°
1.1 L
When cold : 60~70 Nm (600~700 kg.cm, 43~51 lb.ft)
When hot : 70~75 Nm (700~750 kg.cm, 51~54 lb.ft)
Move the timing belt tensioner pulley toward the coolant pump and temporarily secure it.
Install the timing belt on the camshaft sprocket, making sure that the tension side is tightened by turning the camshaft sprocket in reverse. Make sure all timing marks are in alignment.
Adjust the timing according to the "Timing Belt" section.
Install the rocker cover and tighten the bolts to the specified torque.
Tightening torque
Rocker cover bolt :
8 ~ 10 Nm (80 ~ 100 kg.cm, 6 ~ 7 lb.ft)
Install the timing belt cover.
Install the new intake manifold gasket and the intake manifold. Tighten the nuts and bolts to the specified torque.
Tightening torque
Manifold nuts and bolts (both intake and exhaust) :
15 ~ 20 Nm (150 ~ 200 kg.cm, 11 ~ 15 lb.ft)
Install the new exhaust manifild gasket and the exhaust manifold. Tighten the exhaust manifold attaching nuts to the specified torque.
Install the surge tank and tighten the nuts and bolts to the specified torque.
Tightening torque
Surge tank to inlet manifold nuts and bolts :
15 ~ 20 Nm (250 ~ 200 kg.cm, 11 ~ 15 lb.ft)
Install the ignition coil.
Install the air intake hose.
Connect the vacuum hose, fuel hose and coolant hose.
Install breather hose.
