Defects in the cylinder head gasket are determined by various signs.
Warning: Cylinder head bolts must be tightened very carefully. The torque wrench must be checked for accuracy before tightening. The cylinder head bolts must be tightened with a cold engine.
Withdrawal
1. Unhook the drainage casing at the bottom of the engine compartment between the front wall and the windshield and remove it.
2. Disconnect the ground wire (–) battery.
Warning: Before disconnecting, read the instructions in subsection 8.1.3.2.
Warning: In vehicles with air conditioning, the battery is located under the rear seat.
3. Remove poly V-belt.
4. Raise the car.
5. Remove the lower casing of a motor compartment.
6. Loosen the toothed belt and remove it from the camshaft gears. Do not remove the vibration damper.
7. Unscrew the exhaust pipe from the exhaust pipe (arrows show the location of the fasteners).
8. Turn off the gas pipeline at the mechanical valve of the exhaust gas recirculation system (EGR valve). The connection point is located at the left branch pipe next to the oxygen sensor.
9. Drain the coolant.
10. Remove the air hose between the air flow meter and the intake manifold.
11. Unscrew the crankcase ventilation system to the left and right of the cylinder head.
12. Unscrew the fuel inlet and outlet pipes to the left and right of the annular pipeline from below at the intake manifold. Place a rag under the connection and loosen the nuts slowly to relieve pressure. Plug the pipes with appropriate plugs.
13. Unfasten the muffler cover. To do this, insert a wrench between the intake manifold and the cover and slide it up.
14. Turn out both bolts under a cover.
15. Press the muffler cover down, pull it towards the throttle valve and slide it up.
16. Disconnect the following vacuum hoses. To facilitate assembly, pre-mark the hoses with tags.
- vacuum hose to the left of the silencer cover;
- hose of the left connecting pipe of the crankcase ventilation system.
17. Take out the muffler.
18. Mark and remove the following vacuum lines.
- brake booster vacuum line on the right at the intake manifold and at the vacuum pump on the right cylinder head;
- vacuum hose on top of the AGR system box. The box with the mechanical bypass valve is on the lower left side of the intake manifold;
- Vacuum piping of the GRA system box (black plastic box). The GRA system switches the intake manifold valve, the box is located next to the box of the AGR system;
- vacuum line of the activated carbon filter timing valve at the throttle valve;
- vacuum lines at intake manifold changeover valve (blue) and at the electric valve of the EGR system (brown). Both valves are located under the air flow meter.
19. Using an Allen wrench SW 5, unscrew the cover of the valve injector wires on the left.
20. Unclip the throttle linkage, remove and set aside.
21. Remove or disconnect the following wires. For ease of assembly, mark the wires with tags.
- all plugs of spark plugs;
- all valve injector plugs;
- idle speed stabilization valve plug on the lower right at the intake manifold;
- throttle position sensor plug at the bottom of the throttle valve pipe;
- plug for oil pressure sensor and hydraulic switch at the bottom of the left cylinder head;
- connector of the oxygen sensor and the oxygen sensor of the heating system from the end face of the cylinder block, next to the left cylinder head.
Warning: Loosen the wire tie and cut if necessary. Do not remove the clamp so that when assembling the engine, a new band clamp can be installed in the same place.
22. Remove the EGR mechanical valve from the intake manifold.
23. Turn away the holder of the hydraulic pipeline and wires of weight at an inlet collector on the right.
Engines with two valves per cylinder (up to 174 l. With.)
Cylinder head - 6-cylinder petrol engine (2 valves per cylinder, up to 174 hp With.)
- 1. Bolt, 20 Nm
- 2. intake manifold
- 3. Bolt, 10 Nm
- 4. Lid
- 5. Bolt, 10 Nm
- 6. Cylinder head bolt
- 7. Oil pressure sensor, 25 Nm
- 8. Hydraulic switch, 25 Nm
- 9. Hollow bolt, 25 Nm
- 10. Bolt, 10 Nm
- 11. Hall sensor housing
- 12. Cylinder head
The left and right cylinder heads are interchangeable. Therefore, before installation, the head must be provided with a suitable cap.
- 13. Cylinder head gasket
Order of execution
1. Unscrew intake manifold and remove (fastener location is shown by arrows).
2. Cover the holes with one clean rag so that dirt cannot get inside.
3. Remove the coolant pipe at the bottom of the cylinder head.
4. Unscrew the CO sampling tube from the front exhaust pipe and from the bracket.
5. Remove the oxygen sensor.
6. Unscrew the protective heat shield from the outlet pipe.
7. Unscrew the cylinder head cover with an external hexagon wrench SW 5 and remove together with the oil level indicator.
8. Remove the cylinder head cover gasket.
9. Loosen the cylinder head bolts in the reverse order of their numbering, from 8 to 1, first 1/2 turn, then turn out.
Engines with five valves per cylinder (with a working volume of 2.8 l (30 valves), 193 l. With.)
1. Remove the camshaft and valve injector adjustment plug (the location of the fasteners is shown by arrows).
2. Cut the cable tie at the valve cover, unfasten the wire clamp at the injection line, remove the crankcase ventilation system from the cylinder head cover.
3. Remove the four fuel rail bolts at the intake manifold.
4. Detach the fuel inlet and outlet pipes from the holder.
5. Pull out and set aside the fuel manifold with valve injectors. Close the valve nozzles with a clean cloth.
6. Unscrew the ignition coils together with the bracket (4 bolts).
7. Place a wooden block approximately 90 mm high under the gas pedal. Unscrew the GRA box (speed controller), remove the ball joint from the throttle actuator.
8. Open the intake manifold.
9. Remove the bottom left toothed belt cover.
10. Remove the two coolant pipe bolts at the cylinder head.
11. Check if all wires and hoses going to the cylinder head are removed.
12. Loosen the cylinder head bolts in the reverse order of their numbering, from 8 to 1, first 1/2 turn, then turn out.
13. Remove the cylinder head and place it on 2 wooden blocks.
14. Remove the cylinder head gasket.
Installation
1. Before installation, clean the cylinder head and cylinder block of seal residues with a suitable scraper. When doing this, pay attention to ensure that dirt does not get into the holes of the cylinder block. Close the holes with rags.
2. Check if there is oil in the holes for the cylinder head bolts, if there is, remove it. Check the cylinder head with a steel ruler for deflection. Check the deflection with a steel ruler and feeler gauge at various points in the cylinder head. The maximum allowable unevenness should not exceed 0.1 mm.
Warning: If the contact surfaces of the cylinder head are before machined, then the allowable height of the machined head must not be less than a certain minimum height. Minimum height of refinished cylinder head 132.75 mm (for an engine with a displacement of 2.8 liters and 30 valves - 139.25 mm).
3. Check that the holes for the cylinder head bolts are free of oil, remove the oil if necessary. If it is not possible to blow out the holes with compressed air, then you need to take a small screwdriver and a well-absorbing rag and use them to clean the holes of oil.
4. Be sure to replace the cylinder head gasket. The inscription on the gasket must face the cylinder head. Lay the gasket dry and on a dry surface so that the holes in the cylinder block are not blocked.
5. Guide bushings are provided to center the seal and cylinder head.
6. Reserve the correct locations for the guide bushings.
Warning: If a new cylinder head is being installed, a plug must be installed from the front end beforehand. This is necessary so that the cylinder head installed as a spare part can be installed both on the right and on the left.
7. Lubricate the outer edge of the plug with sealant AMV 1880002. The plug must be deepened using the VW-295 rod so that its outer edge is flush with the mounting chamfer of the cylinder head (the figure shows the location of the plug).
8. Carefully install the head with the help of a hoist.
9. Insert the cylinder head bolts with washers and tighten them by hand. Be sure to replace the cylinder head bolts with new ones.
Engines with two valves per cylinder (up to 174 l. With.)
1. The cylinder head bolts are tightened in two steps. In each step, tighten the bolts in sequence from 1 to 8.
Reception 1: using a torque wrench with a torque of 60 Nm.
Reception 2: without interrupting tightening, tighten in the direction of tightening 1/2 turn (180 degrees) with a locked key. It is allowed to perform this technique as 2 puffs of 90 degrees.
2. When tightening the cylinder head bolts, evaluate the key angle. Place the wrench handle along the cylinder head and turn it in one move to a position perpendicular to the axis of the head (1/4 turn is 90 degrees). Then turn the key further until the key handle is again located along the cylinder head.
Warning: Subsequent retightening of the cylinder head bolts on a warm engine is not required and is not permitted. When installing a replacement cylinder head with the camshaft installed, lubricate the contact surfaces of the bucket tappets and cams after installing the cylinder head.
3. Install the toothed belt.
4. Carefully lubricate with a small screwdriver "Silmate AMV 17400401" four edges - arrow - on the contact surface of the cylinder head.
Warning: Oil hole - A - do not block when doing this.
5. Lightly coat the contact surfaces of the cylinder head cover seal with anti-slip agent D00700001 before installation.
6. Install the cylinder head cover together with the oil level indicator and evenly tighten the bolts to a torque of 10 Nm.
Engines with five valves per cylinder (with a working volume of 2.8 l (30 valves), 193 l. With.)
1. The cylinder head bolts are tightened in two steps. In each step, tighten the bolts in sequence from 1 to 8.
Reception 1: using a torque wrench with a torque of 60 Nm.
Reception 2: without interrupting tightening, tighten in the direction of tightening 1/2 turn (180 degrees) with a locked key. It is allowed to perform this technique as 2 puffs of 90 degrees.
Warning: Do not re-tighten the cylinder head bolts when the engine is warm.
2. Screw on the coolant coupler and toothed belt guard.
3. Connect the outlet pipe to the outlet pipe.
4. Screw a branch pipe of a cooling liquid behind a head of cylinders.
5. Screw on the CO sampling tube.
6. Install the oxygen sensor.
7. Remove the cloth from the inlets.
8. Install the intake manifold with a new gasket. Bolts tighten in the specified sequence in four steps. The arrow shows the direction of the vehicle.
- Reception 1: 5 Nm;
- Reception 2: 10 Nm;
- Reception 3: 20 Nm;
- Reception 4: 20 Nm.
Warning: On a 2.8 l engine with 30 valves, only tighten the intake manifold with a torque of 10 Nm.
9. Use a 5 hexagon wrench to screw on the left cover of the valve injector wires.
10. Insert, install or secure the following wires as marked on the tags:
- all plugs of spark plugs;
- all valve injector plugs;
- idle speed stabilization valve plug on the lower right at the intake manifold;
- throttle position sensor plug at the bottom of the throttle valve pipe;
- oil pressure sensor and switch plug at the bottom of the left cylinder head;
- Hall sensor plug at the bottom of the left cylinder head;
- oxygen sensor and oxygen sensor heater plug at the end of the cylinder block, near the left cylinder head.
11. Screw the retainer for the hydraulic line and ground wires at the intake manifold on the right.
12. Screw the EGR mechanical valve to the intake manifold.
13. Install the throttle.
14. Screw on the left cover of the valve injector wires.
15. Install the following vacuum lines as marked on the labels:
- brake booster vacuum line on the right at the intake manifold and at the vacuum pump on the right cylinder head;
- vacuum hose on top of the AGR system box. The box with the mechanical bypass valve is on the lower left side of the intake manifold;
- Vacuum piping of the GRA system box (black plastic box). The GRA system switches the intake manifold valve, the box is located next to the box of the AGR system;
- vacuum line of the activated carbon filter timing valve at the throttle valve;
- vacuum lines at intake manifold changeover valve (blue) and at the electric valve of the EGR system (brown). Both valves are located under the air flow meter.
16. Install at the throttle and screw on the muffler. Attach the muffler cover.
17. Connect the following vacuum hoses according to the markings on the tags:
- vacuum hose to the left of the silencer cover;
- hose of the left connecting pipe of the crankcase ventilation system.
18. Install an air hose between the air flow meter and the intake manifold.
19. Screw the crankcase ventilation system to the left and right of the cylinder head.
20. Screw the pipes for supplying and discharging fuel.
21. Screw the gas supply pipe to the exhaust pipe to the mechanical valve of the exhaust gas recirculation system (EGR valve).
22. Install the lower engine compartment cover.
23. Connect ground wire (-) battery. Enter the anti-theft code and also program the radios.
Warning: The battery can only be connected when the ignition is off, otherwise the injection system control unit will fail.
24. Hook on the drainage cover, and also install the rear seat.
25. Fill with coolant. Always update the coolant.
26. Check engine oil level. If the cylinder head gasket is defective, change the oil.
27. Warm up the engine to normal operating temperature, check the coolant level again, and check all hose connections for leaks.
Features of the right cylinder head (only 174 hp engines. With.)
1. Remove the vacuum pump and plug.
2. Remove the intermediate flange.
3. Pull the piston out of the camshaft.
4. Replace O-rings A, B, C and D.
5. Reinstall piston, intermediate flange and vacuum pump and tighten to 10 Nm.
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