Withdrawal
1. Remove the battery protective cover (see arrows in illustration). If the protective cover is not provided, then remove the fairing.
4.1. Remove the battery protective cover (see arrows)
2. Disconnect the wire terminal «masses» (-) from the negative pole of the battery (see arrow in illustration).
4.2. Disconnect wire terminal «masses» (-) from the negative pole of the battery (see arrow)
3. Remove the front bumper (see relevant chapter).
4. Set the front cross member to the service position (see Section 2C, paragraphs 3.1-3.6).
5. Drain the coolant.
6. Disconnect a reception pipe from a final collector.
7. Cars with an afterburning system. Left cylinder head. Unscrew the bolts 1 of the fresh air intake valve to the exhaust valves (see illustration).
4.7. Unscrew the bolts 1 of the fresh air intake valve to the exhaust valves. Left cylinder head. Vehicles with an afterburning system
8. Remove the timing belt (see relevant chapter).
9. Remove the camshaft gear.
10. Unscrew the mounting bolts (see arrows in illustrations 4.10 and 4.10a) and remove the left/right parts of the rear timing gear cover.
4.10. Unscrew the fastening bolts (see arrows) and remove the left side of the rear protective cover of the timing gear | 4.10a. Unscrew the fastening bolts (see arrows) and remove the right side of the rear protective cover of the timing gear |
11. Remove the intake manifold (see relevant chapter).
12. Left cylinder head. Disconnect the crankcase ventilation hose (see arrows in illustration).
4.12. Disconnect the crankcase ventilation hose (see arrows). Left cylinder head
13. Disconnect the camshaft position sensor plug (hall sensor a), as well as the camshaft positioner valve plug.
14. Cars with an afterburning system. Left cylinder head. Disconnect the coolant hose 3, then disconnect the low pressure hose 1 from the fresh air inlet valve to the exhaust valves, unscrew the connecting fitting 4, unscrew the bolts 2 and remove the valve, unscrew the bolt 5 (see illustration).
4.14. Disconnect the coolant hose 3, then disconnect the low pressure hose 1 from the fresh air intake valve to the exhaust valves, unscrew the connecting fitting 4, unscrew the bolts 2 and remove the valve, unscrew the bolt 5. Left cylinder head. Vehicles with an afterburning system
15. Cars with an afterburning system. Right cylinder head. Disconnect the low pressure hose 4 from the fresh air intake valve to the exhaust valves, then unscrew the bolts 3 and also the bolt 1 of the connecting pipe holder (see illustration).
4.15. Disconnect the low pressure hose 4 from the fresh air inlet valve to the exhaust valves, then unscrew the bolts 3 as well as the bolt 1 of the connecting pipe holder. Right cylinder head. Vehicles with an afterburning system
16. Unscrew the two bolts 6 (see illustration 4.14) or two bolts 2 (see illustration 4.15) holder of the pipeline of the cooling system. It is not necessary to completely disconnect the pipeline.
17. Left cylinder head. Unscrew the bolts (see arrows in illustration) fastenings and disconnect the pipeline of system of cooling from a head of the block of cylinders.
4.17. Unscrew the bolts (see arrows) fastenings and disconnect the pipeline of system of cooling from a head of the block of cylinders. Left cylinder head
18. Right cylinder head. Disconnect the pressure line from the power steering pump and the cylinder head cover (see arrows in illustration).
4.18. Disconnect the pressure line from the power steering pump and the cylinder head cover (see arrows). Right cylinder head
19. Unscrew bolts of fastening and remove a cover of a head of the block of cylinders.
20. Weaken an inhaling, and then unscrew completely bolts of fastening of a head of the block of cylinders in the sequence specified in an illustration.
4.20. Loosen the tightening, and then completely unscrew the cylinder head bolts in the sequence shown
Installation
Installation of a head of the block of cylinders is made in sequence, return to removal.
21. Check up a condition of a head of the block of cylinders and be convinced of absence of cracks and gouges.
22. Clean the threads of the holes for the cylinder head bolts. These holes must be free of oil or other contaminants. If necessary, blow out the holes with compressed air or clean with a screwdriver wrapped in rags that absorb liquid. Oil can be collected from the holes with a grease gun. If this is not done, then when the mounting bolts are screwed in, excess pressure will be created in the holes, which can lead to a rupture of the cylinder block or an incorrect tightening torque of the bolts.
23. Remove the remnants of the old seal from the surface of the cylinder block and head using a plastic scraper. Keep dirt and seal residues out of the cylinder bores. Close the cylinder bores with rags.
Attention! Cleaning of sealing surfaces with a metal brush or other metal tool is not allowed.
24. Check the cylinder head for distortion, deformation or warpage using a feeler gauge and steel ruler (see illustration). The maximum allowable warping of the head should not exceed 0.1 mm. Modification of the cylinder head is allowed to a minimum size «A», which is 139.25 mm (see illustration 4.24a).
4.24. Check the cylinder head for warping, deformation, or warping with a feeler gauge and steel ruler | 4.24a. Modification of the cylinder head is allowed to a minimum size «A», which is 139.25 mm |
25. Before installing the cylinder head, make sure that both large diameter holes on the camshaft gear mounting plates (see arrows in illustration 4.25) facing inwards and the crankshaft is blocked by the lock pin 3242 (see illustration 4.25a).
4.25. Make sure both large diameter holes on the camshaft gear set plates (see arrows) facing inward | 4.25a. Make sure the crankshaft is locked with lock pin 3242 |
26. Inspect the removed cylinder head gasket and, if the pistons, connecting rods or crankshaft have not been replaced, install a new gasket of the same thickness as the old one. Marking inscription «Oben/Top» on the gasket, when laying it, it must be directed upwards, towards the cylinder head.
27. Check that the dowel pins are in the correct position (see arrows in illustration).
4.27. Make sure the dowel pins are in the correct position (see arrows)
28. The purchased new cylinder head can be installed on both the right and left cylinder block. The hole on the front side of the head should be plugged. To do this, apply sealant to the mating surface of the plug, and then install the plug into the hole using a suitable mandrel, such as a mandrel, catalog number 295 (see illustration).
4.28. Install the plug into the hole on the end face of the cylinder head using a suitable drift
29. Apply a small amount of sealant to the areas indicated by the arrows in the illustration.
4.29. Apply a small amount of sealant to the areas indicated by the arrows
30. Tighten the cylinder head bolts in several passes in the sequence shown in the illustration:
- 1st pass - tighten the bolts with a force of 60 Nm;
- 2nd pass - tighten the bolts by 90°;
- 3rd pass - Tighten the bolts 90°.
4.30. Tighten the cylinder head bolts in several passes in the sequence shown
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