Cylinder head. diesel engine
- 1 cylinder head gasket. Pay attention to the labeling.
- 2 bolts, 20 Nm
- 3 cylinder head. Not subject to processing.
- 4 eyes
- 5 cylinder head bolt. Should definitely be replaced. The bolts are tightened in the sequence corresponding to the 4-cylinder gasoline engine
- 6 oil separator
- 7 cylinder head cover. The seal is vulcanized. If damaged, the entire cylinder head cover must be replaced.
- 8 case
- 9 oil fill cap. Replace the seal if the tightness is broken.
- 10 to suction hose
- 11 clamp
- 12 pressure control valve
- 13 seal. Replace if damaged.
- 14 collar nut, 10 Nm. Lubricate the mating surface if the nut does not reach the stop
- 15 top sealing washer. Replace if damaged.
- 16 lower sealing cone
- 17 fuel lines. Fuel lines must be replaced as a set. Do not change the shape of the fuel lines. Tightening torque 25 Nm.
- 18 vacuum pump. For brake booster.
- 19 bolt, 20 Nm
- 20 seal. Should definitely be replaced.
Withdrawal
Warning: Operations and instructions applicable to all engines are given in the section for 4-cylinder petrol engines. This subsection only describes the differences related to the diesel engine.
1. Remove the V-belt, refer to subsection Removing and installing the V-belt.
2. Disconnect the electrical wires from the stop device and spark plugs.
3. Clean the fuel lines at the injection pump connections with a cold cleaner and disconnect them. Close the holes with caps.
Warning: Use a rag to wipe up spilled engine oil. Disconnect the oil supply and return pipes from the turbocharger. Cover the pipelines with polyethylene and rubber rings to prevent dirt from entering.
4. Disconnect the oil supply pipe to the turbocharger at the holders and the oil filter holder.
5. Turn away bolts of fastening and remove the holder of a pipe of a cooling liquid. Remove the pipe.
Warning: Clean up spilled diesel fuel with a rag. Disconnect fuel hoses (arrows) injection pump. When doing this, loosen the clamps with pliers, eg HAZET 798-5. Cover the pipelines with polyethylene and rubber rings to protect them from dirt.
6. Disconnect the connector -2- of the pressure/temperature sensor at the suction pipe.
7. Disconnect the air supply pipe -1- from the cylinder head.
8. Remove the top timing belt cover.
9. Remove the two bolts securing the toothed belt cover at the rear on both sides of the cylinder head.
10. Turn the engine to TDC and remove the toothed belt from the camshaft pulley, refer to subsection Setting the piston of the first cylinder to TDC.
11. Remove the camshaft timing belt pulley, refer to subsection Removal and installation of a gear belt.
12. Fully unscrew the tension roller nut.
13. The diesel engine has cylinder head bolts with internal slots. Therefore, to unscrew them, a special key is required, for example, HAZET 990 Sig-12. Loosen the bolts in the reverse order of their numbering, i.e. from 10 to 1.
14. With the help of assistants, remove the cylinder head from the side of the toothed belt guard and at the same time remove the tension roller.
Installation
1. Diesel engine cylinder heads cannot be machined.
2. To center the cylinder head, use a 3070 screwdriver to screw the guide pins AUDI–3070/9 into the outer holes of the mounting bolts. Note: If the specified pins are not available, old sheared cylinder head bolts can be used instead. To unscrew the fingers obtained in this way, it is recommended to make slots for a screwdriver on the bottom.
3. Depending on the excess of the pistons in thickness, various cylinder head gaskets are installed. When replacing a gasket, pay attention to its marking and use a new gasket only with the same marking. Arrow -1-: Spare part number, arrow -2-: Control code (don't pay attention), arrow –3–: = marking (holes).
4. If new pistons are installed, check the piston height and apply a new gasket accordingly (service station work).
5. With the help of an assistant, insert the cylinder head into the toothed belt guard and at the same time put on the tensioning roller.
Warning: When installing the cylinder head, do not bend the rear gasket tabs with the exhaust manifold heat shield.
6. The cylinder head bolts are tightened in four steps in sequence from 1 to 10. The tightening torques are given in the Specifications.
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