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Cylinder Head
Perform the removal of the cylinder head on the cold engine. Burned or defective cylinder head gasket is determined by the following features: - Reduction of engine power; - Decrease in the coolant level - from the exhaust pipe is white steam; - Reduced level of engine oil; - The presence of oil in the engine cooling fluid: oil becomes gray and foaming, the oil level rises; - The presence of engine oil in the coolant; - Intense bubbling / boiling coolant; - A reduction in the compression of two adjacent cylinders of the engine.
WARNINGS When installing the cylinder head is necessary to use new bolts. All clips and clamps that when removing damaged or cut, when installing the cylinder head replaced. When installing a new head with established camshafts contact cam surface of a camshaft and pushers of valves should be lubricated with engine oil. Plastic caps to protect the open valves must not be removed before the installation of the cylinder head. When replacing the cylinder head must be replaced coolant. Before removing the cylinder head, ensure that all hoses, pipes and electric sockets are disconnected from it. |
When installing the cylinder head, consider the following.
| Fig. 2.3.67. Cylinder head: 1 - cylinder head gasket; 2 - cylinder head; 3 - lifting eye; 4 - bolt 25 Nm; 5 - fingers to install the intake manifold; 6 - the bolts of the cylinder head; 7 - a lining; 8 - the inlet manifold; 9 - a bolt 10 Nm; 10 - oil filler cap; 11 - a lining; 12 - seal; 13 - the cylinder head cover; 14 - bolt 10 Nm; 15 - the cylinder head cover; 16 - a lining of the cylinder head cover; 17 - combined valve EGR; 18 - bolt 10 Nm; 19 - a lining; 20 - bolt 10 Nm; 21 - Rear pipe cooling system; 22 - a sealing ring; 23 - cover
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When the gasket 1, 7, 19, O-ring 20 and bolts 6 (Fig. 2.3.67) must be replaced. Tightening the bolts securing the intake manifold 9 are gradually crosswise. If damaged, replace the gaskets 11 and 16. Tightening bolts 10 spend in a particular sequence. Before installing the gasket 16, apply a thin coat of sealant AMV 174 004 01 at certain points of the cylinder head.
Removing the left cylinder head
A WARNING All clips and clamps that when removing the cylinder head will be damaged or cut, the assembly must be replaced with new ones. |
Removing the cylinder head is made with the engine mounted on the vehicle. Make sure the engine is cold. Otherwise, let it cool down. Switch off the ignition and disconnect a wire of "weight" from the storage battery. Remove the front bumper. Install the front transverse panel in service position (see. "Body"). Drain the coolant. Remove the left reception exhaust pipe.
Vehicles with exhaust gas recirculation Remove the three screws on the EGR valve.
All models Remove the timing belt from pulleys. Remove a pulley of a gear belt from a camshaft.
| Fig. 2.3.68. Location bolts left the back of the toothed belt
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Remove the intake manifold. Disconnect from a head crankcase ventilation hoses. Disconnect the electrical connectors from the Hall sensor and valve variable valve opening valves.
| Fig. 2.3.69. Location hoses and bolts: 1 - a vacuum hose; 2, 5 - bolts; 3 - coolant hose; 4 - coupling; 6 - the bolt of the rear pipe cooling system
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Vehicles with exhaust gas recirculation Disconnect the vacuum hose 1 from the EGR valve. Remove the coupling 4. 2 Remove the screws and remove the EGR valve. Remove the bolt 5.
All models Remove the bolt 6 (see. Fig. 2.3.69) securing the rear pipe cooling system on the cylinder head. Remove the mounting bolt front pipes of the cooling system on the cylinder head. Remove the cover from the left cylinder head.
| Fig. 2.3.70. Sequence of loosening bolts left and right cylinder heads
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In the sequence shown in Fig. 02/03/70 gradually loosen, and then turn out completely the bolts of the cylinder head. Remove the cylinder head and place it on a soft base.
Removal of the right cylinder head
A WARNING All clips and clamps that when removing the cylinder head will be damaged or cut, the assembly must be replaced with new ones. |
Removing the cylinder head is made with the engine mounted on the vehicle. Make sure the engine is cold. Otherwise, let it cool down. Switch off the ignition and disconnect a wire of "weight" from the storage battery. Remove the front bumper. Install the front transverse panel in service position (see. "Body"). Drain the coolant. Remove the right reception exhaust pipe. Remove the timing belt. Remove a pulley of a gear belt from a camshaft.
| Fig. 2.3.71. Location bolts right back of the toothed belt
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Remove the bolts right back of the toothed belt (see. Fig. 2.3.71). Remove the intake manifold.
Vehicles with exhaust gas recirculation
| Fig. 2.3.72. An arrangement of bolts (1, 2 and 3) and the vacuum hose (4) EGR valve
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Remove the bolts 3. Remove the screws 1 bracket connecting pipe.
All models Remove the screws 2 (see. Fig. 2.3.72) fixing the pipe cooling system. Disconnect the electrical connectors from the Hall sensor and valve variable valve opening valves. Disconnect the power steering pipe from the cylinder head and close the cap.
| Fig. 2.3.66. Location nuts (1 and 2) from the cylinder head cover
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Remove the bolts and remove the cylinder head cover (see. Fig. 2.3.66). In the sequence shown in Fig. 02/03/70 gradually loosen, and then turn out completely the bolts of the cylinder head. Remove the cylinder head and place it on a soft base.
Preparation of the cylinder head to be installed 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 into the channels of lubrication systems and cooling. This is especially important for greasing system as the deposit can block oil giving to engine components. If necessary, clean the channels.
A WARNING All clips and clamps that when removing the cylinder head will be damaged or cut, the assembly must be replaced with new ones. |
Check the gasket surface of the head and cylinder block: they should not be nicks, deep scratches and other damage. Small defects can be eliminated by machining. If major defects parts must be replaced. The cylinder head having cracks between the valve seats or between valve seat and the spark plug hole, can be used if the crack width of 0.3 mm or damaged to four of the first threads of the spark plug. Using a metal ruler and a feeler gauge, check the flatness of the mating surfaces. If the flatness exceeds 0.1 mm, the head must be reground. 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. A new cylinder head gasket unwrap just before installation. If you were working on the timing, turn the hand crank shaft on two complete revolutions, to ensure that the pistons do not strike the valves.
Setting Carried out in sequence, return to removal, taking into account the following.
| Fig. 3.2.29. Location large holes fixing plates on pulleys of camshafts
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Before installation of the cylinder head, set the first cylinder and the camshaft at TDC in the compression stroke. At the same time the larger hole of the fixing plate on the camshaft pulley should be directed to the center of the engine (see. Fig. 3.2.29).
| Fig. 3.2.30. Set screw 3242 for fixing the crankshaft
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Secure crankshaft in this position by removing the cylinder from the crankshaft position sensor and screwing instead set screw 3242 (see. Fig. 3.2.30). Place the gasket on the guide pins, with the inscription ?�oben?� (?�up") must be directed to the head. Install the cylinder head to the engine. Insert the bolts of the cylinder head and tighten them by hand. In the reverse loosening, tighten the bolts of the cylinder head in two stages (see. Fig. 2.3.70): Stage 1 - tighten to 60 Nm; Stage 2 - tighten on a corner 180 ?�. Additional tightening the cylinder head bolts after the engine warms up, or after a certain time is required. Screw mounting fingers intake manifold. Install the intake manifold. Connect the vacuum hoses. Install the cylinder head cover. When installing the guide tube for oil dipstick, install a new O-ring. Install the timing belt and adjust its tension. Install poly V-belt. Establish a reception exhaust pipe. Fill the cooling system with coolant. 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 press all the switches window again, at least 1, in the closed position of the control unit to activate windows. Set the clock.
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