Cylinder Head

Withdrawal

Perform the removal of the cylinder head on the cold engine.

If cylinder head is removed from the engine mounted on the vehicle, set the front transverse panel in service position.

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.

Switch off the ignition and disconnect a wire of "weight" from the storage battery.

Drain the coolant.

Remove the intake manifold.

Remove poly V-belt and V-ribbed belt tensioner.

Remove the air filter cover (see. Fig. 3.1.3).

Disconnect and move aside the electrical connections (see. Fig. 3.1.12):

1 - the engine of the secondary air pump (for motor ANB);

2 - from the valve ACF;

3 - from the switch;

4 - from the air flow meter;

5 - the solenoid valve pressure.

Disconnect hoses and remove the air filter housing (see. Fig. 3.1.12).

Disconnect the electrical connector from the coolant temperature sensor.

Disconnect the vacuum hose from the combination valve (only for motor ANB).

Disconnect the cylinder head all the electrical connectors and move them aside.

Disconnect from the front of the cylinder head cover and the hose bent pipe 2 (see. Fig. 3.1.55) crankcase ventilation and move it aside.

Disconnect the pipe 1 (see. Fig. 3.1.55) of the combined charge air valve on the cylinder head cover and on thermofilter (only on engines ABN). Take the tube side.

Remove the bolts and remove thermofilter 3 (see. Fig. 3.1.55).

Remove bolts 1 and 2 (Fig. 3.1.59) securing the supply oil line.

3 Remove the screws securing the turbocharger.

Release clamps and remove the hose from the back of the cylinder head to the radiator heater.

Remove the top casing of a gear belt.

Turning the crankshaft in the direction of its working rotation of the pulley bolt, install the piston of the first cylinder in the top dead center (TDC). Make sure that the mark on the camshaft pulley combined with the index on TDC cylinder head cover and the label of the crankshaft combined with the index on the housing (see. Fig. 3.1.39).

Loosen the timing belt.

Allen key 8 mm slowly turn counterclockwise toothed belt tensioner pulley to align the holes 2 (see. Fig. 3.1.43) in stock and housing tensioner. In this position, insert into the holes T40011 mandrel or a steel rod with a diameter of 1.5 mm. Do not loosen the bolts 3.

Remove a gear belt from a camshaft pulley.

Remove the cylinder head cover.

In sequence, return to a tightening, loosen and then turn out completely the bolts of the cylinder head (Fig. 3.1.60) .Snimite 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 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.

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.

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. The height of the cylinder head as well (Fig. 3.1.61) after machining should be for the four-cylinder engine of at least 139.25 mm.

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.

Setting

Installation is spent to sequences, return to removal, taking into account the following.

Bolts cylinder head must be replaced.

When installing the cylinder head and must be replaced with new all O-rings, gaskets and self-locking nuts and bolts are tightened dovorachivaniem at a certain angle.

A new cylinder head gasket unwrap just before installation.

Before installing the cylinder head and crank set the camshafts to a position corresponding to the TDC of the first cylinder. Make sure that the mark on the camshaft pulley combined with the index on TDC cylinder head cover and the label of the crankshaft combined with the index on the housing (see. Fig. 3.1.39).

Loosen the two bolts turnover rack support turbocharger.

Place the gasket on the guide pins, with the inscription ?�oben?� (?�up") must be directed to the head.

Install the cylinder head.

Insert the bolts of the cylinder head and tighten them by hand.

In the sequence shown in Figure 3.1.60, in two stages, tighten the bolts of the cylinder head:

Stage 1 - tighten bolts to 60 Nm;

2nd stage - to tighten them at an angle of 180 ?�.

Additional tightening the cylinder head bolts after the engine warms up, or after a certain time is required.

Attach a new seal to the turbocharger to the exhaust manifold and tighten the bolts attaching the stand to support the turbocharger.

Install the cylinder head cover.

Install the timing belt and adjust its tension.

Install poly V-belt and adjust its tension.

Install the intake manifold.

Vehicles with accelerator cable

Adjust the accelerator cable.

All models

Fill with new coolant.

Attach the 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 the windows all switches again, at least 1, in the closed position to activate the window control block.

Set the clock.