Pic. 3.4–52. Cylinder head: 1 - front middle pipe of the cooling system; 2 - bolt, 10 Nm; 3 - sealing ring; 4 – a head of the block of cylinders; 5 - guide sleeve; 6 – bolts of fastening of a head of the block of cylinders; 7 - connecting pipe of the exhaust gas recirculation system; 8 - bolt, 10 Nm; 9 - gasket; 10 - pipe of the crankcase ventilation system; 11 - bolt, 10 Nm; 12 - vacuum pump; 13 - bolt, 10 Nm; 14 - sealing rings; 15 – bolt, 20 Nm + tighten by 90°; 16 - gasket; 17 - guide pipe for the pointer (probe) oil level; 18 - bolt, 10 Nm; 19 – a lining of a head of the block of cylinders
Pic. 3.4–53. Arrangement of bolts of fastening of the left pipe of recirculation of the fulfilled gases and a turbocharger to an exhaust manifold
Unscrew the bolts and disconnect the left EGR pipe (see fig. 3.4–53).
Unscrew the bolts securing the turbocharger to the exhaust manifold (see fig. 3.4–53).
Unscrew bolts of fastening of the fuel heat exchanger.
Disconnect an average pipe of system of cooling from the back party of a head of the block of cylinders.
Pic. 3.4–50. Fuel return line location (1) and electrical connectors (2–7).
Disconnect the electrical connectors from the injectors (see fig. 3.4–50).
Unscrew the wire clamp and move the wires to the side (see fig. 3.4–50).
Release the fuel supply line 1 from the clamps (see fig. 3.4–50) and remove it from the injectors.
Pic. 3.4–51. Mounting clamp location (1) fuel hose to T-piece and fuel line mounting (2) to the fuel supply pump
Loosen the clamp and remove the fuel hose from the T-piece (see fig. 3.4–51).
Remove the spring clip and disconnect the fuel line from the supply fuel pump (see fig. 3.4–51).
Disconnect the fuel lines near the right cylinder head cover.
Unscrew the oil filler cap.
Pic. 3.4–43. The location of the notch in the oil filler hole
For the crankshaft pulley bolt, turn the shaft until a notch is visible in the oil filler hole (see fig. 3.4–43).
Pic. 3.4–44. Arrangement of bolts of fastening of casings of fuel atomizers
Unscrew the bolts securing the injector shrouds, pull the shrouds up and turn them 90°counterclockwise (see fig. 3.4–44).
Pic. 3.4–45. Location of fuel injector mounting bolts
Unscrew the exposed injector mounting bolts (see fig. 3.4–45).
Pull up and remove the injectors of cylinders 1 and 3. When removing the injectors, you can use the lever.
Turn the crankshaft clockwise 180°and remove the injectors for cylinders 2 and 4.
Pic. 3.4–46. Arrangement of bolts of fastening of a cover of a head of the block of cylinders
Unscrew the bolts and remove the right cylinder head cover (see fig. 3.4–46).
Pic. 3.4–55. Arrangement of bolts of fastening of a directing roller and a back casing of a gear belt
Unscrew bolts and remove back casings of a gear belt (see fig. 3.4–55, 3.4–58).
Pic. 3.4–58. Arrangement of bolts of fastening of a back casing of a gear belt
Disconnect fuel lines from injection pump.
Disconnect the electrical connector from the coolant temperature sensor.
Unscrew bolts and remove an average pipe of system of cooling.
Unscrew bolts and remove a cover of the right head of the block of cylinders (see fig. 3.4–46).
Pic. 3.4–57. Arrangement and sequence of an inhaling of bolts of fastening of a head of the block of cylinders
Unscrew the bolts and remove the right cylinder head (pic. 3.4–57).
Preparing the head for installation
The mating surfaces of the head and cylinder block must be perfectly clean. Use a hard plastic or wooden scraper to clean them. Be careful when cleaning as aluminum alloy is very easy to damage. Check that carbon deposits do not get into the oil channels and channels of the cooling system. This is especially important for the lubrication system, as deposits can block the oil supply to engine parts. Clean channels if necessary.
Check the mating surfaces of the cylinder head and block for nicks, deep scratches and other damage. Small defects can be eliminated by machining. In case of significant defects, replace parts.
Clean the bolt holes in the block. Screwing a bolt into an oil-filled hole may cause the block to rupture due to excessive hydraulic pressure.
Installing the cylinder head
At installation it is necessary to use new bolts of fastening of a head of the block of cylinders.
All clips and clamps that were damaged or cut when removing the engine must be replaced with new ones.
When installing, replace with new self-locking nuts and bolts, which were tightened by tightening to a certain angle, as well as sealing rings and gaskets.
Check the flatness of the mating surface of the cylinder head.
When replacing the cylinder head and its gasket, fresh coolant must be added to the cooling system.
A new cylinder head gasket must be removed from the packaging immediately before installation.
Pic. 3.4–59. Measurement of piston protrusion from the cylinder block
If new pistons are installed on the engine, it is necessary to measure the protrusion of the pistons from the cylinder block (pic. 3.4–59).
Pic. 3.4–60. Marking the cylinder head cover gasket with holes (1), number (2) and installation side (3)
Based on the protrusion of the pistons, the thickness of the new cylinder head gasket is selected (pic. 3.4–60).
Protrusion of pistons, mm | Number of holes |
0,39–0,49 | 1 |
0,49–0,54 | 2 |
0,54–0,65 | 3 |
Install the gasket on the guide pins, while the inscription «oben» should point towards the head.
If work has been done on the valve train, turn the engine two full turns by hand to make sure the pistons do not hit the valves.
Pic. 3.4–61. Location of set screw 3242 to fix the crankshaft
Before installing the cylinder head, set the piston of the first cylinder and the camshaft to TDC on the compression stroke. Lock the crankshaft in this position. To fix the crankshaft from the cylinder block, unscrew the fuel injection timing sensor and replace it with set screw 3242 (pic. 3.4–61).
Using a screwdriver blade as a lever, remove the cover covering the end of the camshaft on the cylinder head.
Pic. 3.4–36. The location of the retainer 3458, which determines the position of the camshaft
Replace the cap with retainer 3458, which determines the initial position of the camshaft (see fig. 3.4–36).
Insert the cylinder head bolts and tighten by hand.
In the sequence shown in Figure 3.4–57, tighten the cylinder head bolts in four steps:
- 1st - torque 35 Nm;
- 2nd - torque 60 Nm;
- 3rd - tighten by an angle of 90°;
- 4th - tighten by an angle of 90°
In the future, additional tightening of the cylinder head bolts is not required.
Left cylinder head
When installing the guide tube for the pointer (probe) oil level, a new O-ring must be installed.
Both cylinder heads
Install the toothed belt.
Install the cylinder head cover.
Fill with fresh coolant.
Connect wire «masses» to the battery.
Turn on radio and enter the code into it.
Raise the windows with the power windows up to the stop. Then press all power window switches again for at least 1 second to the closed position to activate the power window control unit.
Set the time on the clock.
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