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Cylinder heads
| Fig. 3.4.43. Cylinder head: 1 - the cylinder head; 2 - Laying the cylinder head cover; 3 - the bolts of the cylinder head; 4 - cylinder head cover; 5 - slinger ring; 6 - a lining; 7 - a cover; 8 - the fuel injector tube; 9 - the fuel return pipe; 10 - a sealing ring; 11 - banjo bolt 5 Nm; 12 - the inlet manifold; 13 - bolt 10 Nm; 14 - a lining; 15 - centering sleeve; 16 - bolt 10 Nm; 17 - thermofilter vacuum pump; 18 - vacuum pump; 19 - bolt 10 Nm; 20 - a sealing ring; 21 - Cylinder head gasket
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The left cylinder head cover Remove the front section of the intake manifold.
A WARNING All clips and clamps that when removing the cylinder head cover are damaged or cut, when installing the cylinder head cover must be replaced. |
Release and move the wiring harness from the left cylinder head cover. Mark and disconnect fuel tubes from injectors.
| Fig. 3.4.44. Location nuts left cylinder head cover and the fuel return pipe (1)
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Remove banjo bolts and remove the fuel return pipe 1 (fig. 3.4.44) with the sprayers. Unscrew the nuts and remove the left cylinder head cover. Installation is made in sequence, return to removal, taking into account the following. Replace with new O-rings tube of return of fuel. If the gasket is damaged cylinder head cover replace it with a new one. If damaged fuel injector O-rings, replace the cylinder head cover. Degrease, gasket cylinder head cover.
| Fig. 3.4.45. Places applying sealant before installing the cylinder head cover
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Apply a thin continuous layer of sealant on a semicircular surface (Fig. 3.4.45) in the end of the cylinder head. Put a portion of the length of 5 mm and a diameter of 3 mm layer of sealant on the outer cover of the camshaft (see. Fig. 3.4.45). Nuts of fastening of the cylinder head cover gradually tighten crosswise. Connect the fuel pipes. Replace the front section of the intake manifold.
The right cylinder head cover
A WARNING All clips and clamps that when removing the cylinder head cover are damaged or cut, when installing the cylinder head cover must be replaced. |
| Fig. 3.4.1. Location screws engine cover
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Remove the screws and remove the engine cover (see. Fig. 3.4.1). Loosen the hose clamps and remove the air tube from the air filter.
| Fig. 3.4.46. Mounting pipe to the turbocharger
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Mark and disconnect fuel tubes from injectors. Release and move the wiring harness from the right cylinder head cover. Disconnect the vacuum hoses from the turbocharger and the mechanical valve of system of repeated burning of the fulfilled gases. Remove the bolts and remove the pipe connecting the turbocharger air cooler. Remove the bolt tube gauge engine oil.
A WARNING Do not remove the tube engine oil level indicator, as otherwise the O-ring at the base of the tube will be damaged and need to be replaced. |
Remove banjo bolts and remove the fuel return pipe. Remove the nuts and remove the cylinder head cover. Installation is made in sequence, return to removal, taking into account the following. Replace with new O-rings tube of return of fuel. If the gasket is damaged cylinder head cover replace it with a new one. If damaged fuel injector O-rings, replace the cylinder head cover. Degrease the surface mating with seal cylinder head cover. Apply a thin continuous layer of sealant on a semicircular surface on the end of the cylinder head. Put a portion of the length of 5 mm and a diameter of 3 mm layer of sealant on the outer cover of the camshaft (see. Fig. 3.4.45). Nuts of fastening of the cylinder head cover gradually tighten crosswise. Connect the fuel pipes.
Removing the cylinder head
A WARNING All clips and clamps that when removing the cylinder head will be damaged or cut, when installing the cylinder head must be replaced. |
Before disconnecting the battery, check whether you have the code switch on the radio. Switch off the ignition and disconnect a wire of "weight" from the storage battery.
| Fig. 3.4.2. Location screws bottom mudguard of a motor compartment
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Remove the screws and remove the two sections of the bottom mudguard of a motor compartment (see. Fig. 3.4.2). Remove the front bumper. Drain the coolant from the cooling system. On the left front side of the engine compartment, remove the screw fastening the bracket supporting the air-conditioning duct system. Install the front transverse panel in service position.
| Fig. 3.4.4. Location bolts thermofilter of turbocharger
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Remove the screws (see. Fig. 3.4.4) and remove thermofilter on turbocharger.
| Fig. 3.4.5. Location bolts reception exhaust pipe to the turbocharger.
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Remove the bolts a reception exhaust pipe to the turbocharger (see. Fig. 3.4.5). Loosen the hose clamps and remove the front exhaust pipe with catalytic converter. Remove the nut and remove the exhaust pipe connecting the turbocharger to the exhaust manifold. Remove the cylinder head valve EGR.
| Fig. 3.4.15. Unscrewing bolts radiator fan with viscous coupling
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Remove the bolt radiator fan with viscous coupling, keeping the axis of rotation of the fan the other wrench (see. Fig. 3.4.15).
| Fig. 3.4.16. Location housing screws V-ribbed belt
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Remove the screws and remove the cover V-belt (see. Fig. 3.4.16).
| Fig. 3.4.41. Location bolts left section of the intake manifold
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Remove the front section of the intake manifold (see. Fig. 3.4.41). Remove the oil filler cap.
| Fig. 3.4.22. The label on the camshaft during installation in the first cylinder in the compression stroke TDC
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For pulley bolt, rotate the crankshaft in the direction of working rotation until the marking ?�OT?� (TDC) on the camshaft hole in the oil filler (see. Fig. 3.4.22).
| Fig. 3.4.23. Set screw 3242 (1) to lock the crankshaft
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Secure crankshaft in this position. To do this, remove the cylinder TDC sensor, and instead tighten the set screw 3242 (see. Fig. 3.4.23).
| Fig. 3.4.26. An arrangement of bolts (1) securing the shock absorber, the nuts (2) securing the fuel pump and pulley bolt (3) fastening of a pulley of a gear belt to a pulley of the fuel pump
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Remove the damper pulley of the fuel pump (see. Fig. 3.4.26). 2 nut fastening of a pulley of the fuel pump should not turn away, because otherwise change the fuel injection timing.
A WARNING Chalk, markers or paint mark the direction of rotation of the toothed belt. After setting the belt rotates in the opposite direction, which may result in its destruction. |
Loosen toothed belt tension and remove the belt. Disconnect the supply pipe and fuel return from the fuel pump. Loosen the timing belt fuel pump and remove the belt. Remove the bolts and remove the fuel pump. Remove the cap from the V-ribbed belt tensioner compressor.
| Fig. 3.4.17. Location bolts tensioner V-ribbed belt air conditioning compressor
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Loosen the bolt tensioner V-belt air conditioning compressor and remove the belt from the pulley (see. Fig. 3.4.17).
| Fig. 3.4.18. The weakening of the tension of the main V-ribbed belt tensioner and lock pin (1)
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Allen wrench, turn counterclockwise the main tensioner V-ribbed belt to loosen the belt tension. Secure in this position the tensioner pin (pos. 1 fig. 3.4.18) and remove the belt.
| Fig. 3.4.28. Location bolts toothed belt and radiator fan bracket 1 - a bolt, 45 Nm; 2 - bolt 10 Nm; 3 - bolt 20 Nm; 4 - bolt 10 Nm
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Remove the pulley bolt radiator fan with viscous coupling. Remove the screws of the vacuum pump, turn the pump counter-clockwise and remove it from the left cylinder head.
| Fig. 3.4.24. Location lid covering the end of the camshaft on the right cylinder head
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Use a screwdriver as a lever, remove the cover over the end of the camshaft on the right cylinder head (see. Fig. 3.4.24).
| Fig. 3.4.25. Location latch 3458, which determines the position of the camshaft
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Set the lid locks in place 3458 (see. Fig. 3.4.25) camshaft. Unscrew the screws 3 (see. Fig. 3.4.26) fastening of a pulley of a gear belt to a pulley of the fuel pump.
| Fig. 3.4.30. The weakening of the tension of the toothed belt
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Allen wrench to turn the 8 mm toothed belt tensioner pulley clockwise and fix the pin diameter of 2 mm (see. Fig. 3.4.30).
| Fig. 3.4.31. Use puller Kukko 204-1 (1) for the removal of a pulley of a gear belt from a camshaft
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Using puller Kukko 204-1 (see. Fig. 3.4.31), remove both camshaft pulleys to their number of cones. This stripper should rest on the bolts camshaft pulleys. Camshaft pulley must rotate freely on the mounting cones, but do not have excessive play. Remove the bolt and remove the toothed belt pulley with the left cylinder head. Remove the timing belt.
| Fig. 3.4.47. Location screws left (1) and upper (2) and right (3) Rear toothed belt
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Remove the screws and remove the upper section of the rear toothed belt 2 (Fig. 3.4.47). Remove the screws and remove the left and right 1 3 back casing of a gear belt. Remove the screws and remove the front pipe cooling system. Unscrew the nuts and remove the cylinder head cover.
| Fig. 3.4.48. Sequence of loosening bolts of the cylinder head
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In the sequence shown in Fig. 3.4.48 gradually loosen and then completely unscrew the bolts of the cylinder head. Remove the cylinder head and place it on a soft base.
Preparation for the installation of the head The mating surfaces of a head and the block of cylinders should be absolutely clean. For their clearing use a firm plastic or wooden scraper. When cleaning, be careful, as the aluminum alloy is very easily damaged. Make sure that the deposit has not got to oil and water channels. This is especially important for greasing system as the deposit can block oil giving to engine components. If necessary, clean the channels. Check the gasket surface of the cylinder head and the presence of nicks, deep scratches and other damage. Small defects can be removed by machining. If major defects parts must be replaced. Check the flatness of the mating surface of the cylinder head. Clean the bolt holes in the engine block of dirt and oil. Fastening bolt aperture filled with oil can cause a rupture of the bloc of oil pressure.
Installing the cylinder head Installation is spent to sequences, return to removal, taking into account the following. When installing the cylinder head must be replaced all the self-locking nuts and bolts are tightened dovorachivaniem at a certain angle, as well as seals and gaskets. A new cylinder head gasket unwrap just before installation.
| Fig. 3.4.49. Marking gasket cylinder head cover holes (1), room (2) and the source of production (3)
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If the engine is equipped with new pistons, measure the protrusion of the pistons of the cylinder block and in accordance with its value to select the thickness of the new cylinder head gasket (Fig. 3.4.49). Place the gasket on the guide pins, with the inscription ?�oben?� (?�up") must be directed to the head. If you were working on the timing, turn the engine by hand on two complete revolutions, to ensure that the pistons do not strike the valves. Before installing the cylinder head, set the first cylinder and camshafts at TDC on the compression stroke. Secure crankshaft in this position by removing the sensor from the fuel injection timing of the cylinder and replaced by screwing the set screw 3242 (see. Fig. 3.4.23).
The protrusion of the pistons, mm | Number of holes | 0,39-0,49 | 1 | 0,49-0,54 | 2 | 0,54-0,65 | 3 |
| Fig. 3.4.50. Gas distribution mechanism: 1 - a cover of the bearing of the inlet camshaft; 2 - Union nut, 15 Nm; 3 - bolt 10 Nm; 4 - union nut, 15 Nm; 5 - nut 10 Nm; 6 - bolt 10 Nm; 7 - a cover bearing the exhaust camshaft; 8 - inlet camshaft; 9 - exhaust camshaft; 10 - hydraulic pusher; 11 - bolt 10 Nm; 12 - vacuum pump; 13 - persistent half ring; 14 - cylinder head; 15 - exhaust valve; 16 - inlet valve; 17 - a sealing ring; 18 - camshaft pulley; 19 - bolt 75 Nm; 20 - valve stem seal; 21 - valve springs; 22 - support of the valve spring; 23 - crackers; 24 - hydraulic pusher; 25 - a support arm; 26 - the lever
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Insert head bolts 14 (Fig. 3.4.50) cylinder block and tighten them by hand, and then pull the four stages in the reverse order to that shown in Fig. 3.4.48: Stage 1 - 35 Nm; Stage 2 - 60 Nm; 3rd stage - to tighten on 90 ?�; 4th stage - to tighten a further 90 ?�. Additional tightening the cylinder head bolts after the engine warms up, or after a certain time is required. Install the cylinder head cover. Install the timing belt. Bleed the fuel system. Connect a wire of "weight" to the battery. Turn on the radio and enter the code. Lift up the power window glass until it stops. Then click on all window switches again for at least 1, in the closed position of the control unit to activate windows. Set the clock.
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