Warnings
Pic. 3.2–32. Cylinder head: 1 - bolt, 10 Nm; 2 - fuel distributor; 3 - bolt, 20 Nm; 4 - bolt, 20 Nm; 5 - intake manifold; 6 - nut, 10 Nm; 7 – a bolt of fastening of a head of the block of cylinders; 8 – a head of the block of cylinders; 9 - bolt, 10 Nm; 10 - bolt, 10 Nm;
11 - bolt, 55 Nm; 12 – laying of a head of the block of cylinders
When installing the cylinder head with gasket, you must use new bolts 7 (pic. 3.2–32) head mounting.
When replacing the cylinder head, the cooling system must be filled with fresh coolant.
All clips and clamps that will be damaged or cut when removing the engine must be replaced with new ones when installing the cylinder head.
Before disconnecting the battery, find out if you have a radio activation code.
Withdrawal
Removal of a head of the block of cylinders spend on the cold engine.
The battery is located under the luggage compartment floor.
Turn off the ignition and disconnect the wire «masses» from the battery.
Drain the coolant from the engine cooling system.
Remove the left front exhaust pipe.
Pic. 3.2–2. An arrangement of screws of fastening of the bottom mudguard of a motor compartment
Remove the bottom mudguard of the engine compartment (see fig. 3.2–2).
Unscrew the left and right front exhaust pipes.
Pic. 3.2–1. Screw location of the left ventilation grille
Loosen the screw securing the left bumper grille (at the same time, the right lattice is also released) and remove the bars (see fig. 3.2–1).
Remove the toothed belt.
Remove the vacuum hose from the cruise control control unit.
Remove the accelerator cable.
Disconnect the coolant hose from the coolant drain valve.
Pic. 3.2–5. Location of electrical connectors and fuel line fastening elements: 1, 5, 6, 10 – fuel line fastening bolts; 2, 4, 7, 9 - clamps; 3, 8 - electrical connectors for knock sensors
Disconnect electrical connectors 3 and 8 from the knock sensors on the left and right sides of the fuel line (see fig. 3.2–5).
Release the four electrical wire clamps 2, 4, 7 and 9.
Disconnect the electrical connectors from the fuel injectors on the left and right side of the engine.
Turn away bolts 1, 5, 6 and 10 and, being careful, remove a fuel highway.
Pic. 3.2–33. The location of the intake manifold mounting bolts
Loosen the bolts and remove the intake manifold (pic. 3.2–33).
Loosen the left and right exhaust manifold front bolts.
Disconnect the electrical connectors from the ignition coils.
Unscrew and remove the cooling system pipe located between the heads at the rear of the engine.
Pic. 3.2–34. Arrangement of bolts of fastening of a cover of a head of the block of cylinders
Remove cylinder head covers (pic. 3.2–34).
On the left cylinder head, unscrew and remove the guide tube for the pointer (probe) engine oil level.
Pic. 3.2–35. Arrangement of bolts of fastening of a head of the block of cylinders
Gradually loosen and then completely remove the cylinder head bolts (pic. 3.2–35).
Remove the cylinder head and place it on a soft base.
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. Make sure that carbon deposits do not get into the oil and water channels. 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. Minor defects can be eliminated by machining; in case of significant defects, replace the parts.
Using a metal ruler and feeler gauge, check the flatness of the mating surfaces.
If the flatness deviation exceeds 0.1 mm, the head must be reground. Cylinder head height A after machining must be at least 139.25 mm (pic. 3.2–36).
Pic. 3.2–36. Place of measuring the height of the cylinder head
Clean the bolt holes in the block. When screwing a bolt into an oil-filled hole, the block may burst due to hydraulic pressure.
Installation
Installation is carried out in the reverse order of removal, taking into account the following.
Replace the cylinder head bolts.
A new cylinder head gasket must be removed from the packaging immediately before installation.
Install the gasket on the guide pins, while the inscription «oben» or «top» should point towards the head.
Pic. 3.2–37. Cylinder head bolt tightening sequence
Insert the cylinder head bolts and tighten them by hand, and then in the sequence shown in Figure 3.2-37 in three stages:
- 1st - torque 40 Nm;
- 2nd - torque 60 Nm;
- 3rd - tighten by an angle of 180°.
In the future, additional tightening of the cylinder head bolts is not required.
Before installing the intake manifold, connect the front crankcase breather hose.
Before reinstalling the cylinder head cover, grease both sides of the cover gasket with a thin layer of silicone grease D 007 000 04.
Apply a layer of silicone grease D 007 000 04 with a thin screwdriver blade to the transitions near the front and rear camshaft covers (pic. 3.2–38).
Pic. 3.2–38. Places for applying silicone grease D 007 000 04 to the transitions of the faces near the rear covers of the camshafts
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