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The cylinder head engines AVF, AWX
Withdrawal Removing the cylinder head is made on a cold engine. If cylinder head is removed with the engine mounted on the vehicle, set the front transverse panel in service position.
| Fig. 3.3.48. Cylinder head 1 - bolt 10 Nm; 2 - a bolt, 25 Nm; 3 - bolt 100 Nm; 4 - with the rotor hub of the Hall sensor; 5 - the bolts of the cylinder head; 6 - cylinder head cover; 7 - crankcase ventilation hose; 8 - the plug; 9 - Cover; 10 - a sealing ring; 11 - bolt 10 Nm; 12 - a lining of the cylinder head cover; 13 - cylinder head; 14 - bolt 20 Nm; 15 - oil supply line to the turbocharger; 16 - the holder of the fuel filter; 17 - screw terminal; 18 - hollow bolt; 19 - a sealing ring; 20 - cylinder head gasket; 21 - Hall sensor
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Burned or defective gasket 20 (Fig. 3.3.48) of the cylinder head 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. |
A WARNING When you open the cover of a broad tank on the hot engine must be careful, because the pressurized steam can cause severe burns. Close the expansion tank with a thick layer of tissue and slowly remove the lid until the hissing sound. After the cessation of fizz slowly unscrew and remove the cap from the expansion tank. |
Remove the expansion tank cap.
| Fig. 3.3.2. Location engine cover screws and the pointer (1) engine oil level
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Release clamps fastening, remove the three screws and remove the engine cover (see. Fig. 3.3.2). Install the engine oil dipstick in place.
| Fig. 3.3.3. Location air filter cover
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Remove the two screws and remove the air filter cover (see. Fig. 3.3.3).
| Fig. 3.3.46. Arrangement of a bolt (1) securing the air filter housing, the electrical connector (2), an air nozzle (3) and the fastening clamp on the motor AVF and AWX
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Unplug electrical connector 2 (see. Fig. 3.3.46) of the air flow meter. Unscrew clamp wires from the air filter housing and take wires aside. Loosen the clamp and disconnect the air pipe 3 (see. Fig. 3.3.46) from the air filter housing. Remove the bolt 1 (see. Fig. 3.3.46) and remove the air filter housing. Disconnect the air pipe from the turbocharger.
| Fig. 3.3.49. Places overpressure hose connections (1), vacuum valve (2) and intake manifold boost pressure adjustment chamber (3)
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Disconnect hoses from overpressure chamber 1 (Fig. 3.3.49), the vacuum valve 2 and the intake manifold boost pressure adjustment chamber 3. Remove the turbocharger mounting bolts to the catalytic converter. Remove the clamping sleeve front support exhaust system.
A WARNING The connecting element of the exhaust pipe should not be bent more than 10 ?�, otherwise it will be damaged. |
Disconnect the air pipe from the turbocharger.
Remove the screw to release the lock and remove the protective shield of the right drive shaft. Remove the bolts and remove the holder of a turbocharger.
| Fig. 3.3.50. Location pipe bolt from the turbocharger oil return
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Remove the screws and remove the oil return line from the turbocharger (Fig. 3.3.50). Disconnect hoses from the surge tank, radiator and average top tube cooling system.
| Fig. 3.3.13. Location electrical connector (1) and screws (2) fixing the air pipe
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2 Remove the screw (see. Fig. 3.3.13), release and remove the air inlet. Loosen the clamp screw and remove the fuel filter up from the holder and move it to one side with hoses connected. Remove the screws and remove the holder of the fuel filter. Disconnect the hose from the middle top of the pipe cooling system.
| Fig. 3.3.51. Location nuts average top tube (1) cooling system
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Remove the nut and remove the upper middle tube 1 (Fig. 3.3.51) of the cooling system. Disconnect the electrical connectors from the spark plugs. Disconnect the vacuum hose from the vacuum brake booster bulkhead.
| Fig. 3.3.52. Location nuts (3) fixing the electrical connector and fuel hoses (1 and 2)
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Turn the knurled nut (Pos. 3 in Fig. 3.3.52) fixing the electrical connector and disconnect the connector.
| Fig. 3.3.53. Location bolts tap the oil pipeline to the base of the oil filter
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Remove the bolt-pass oil pipeline to the base of the oil filter (Fig. 3.3.53).
| Fig. 3.3.54. Designated connecting hoses (1 and 4) cooling system, electrical connector (3) and clips (2) leads to the cylinder head
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Disconnect hoses 1 and 4 (Fig. 3.3.54) of the cooling system of the cylinder head. Disconnect the electrical connector 3 from the cylinder head. 2 Remove the bolt clamping the wire harness and move aside. Remove the timing belt. Turn out bolts and remove a pulley of a gear belt from the hub on the camshaft.
| Fig. 3.3.55. Unscrewing bolts (1) securing the timing belt pulley hub shaft kraspredelitelnomu
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Remove the screw 1 (Fig. 3.3.55) fixing the toothed belt pulley hub two turns, hold the hub from turning tool T10051.
| Fig. 3.3.56. Use puller T10052 (2), fixed with screws (1) on the hub of the pulley of a gear belt, to remove the hub cone camshaft
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Install the puller T10052 (pos. 2 in Fig. 3.3.56), securing it in the threaded hole for the screws on the hub of the pulley. Align the screws 1 (see. Fig. 3.3.56), a stripper with threaded holes of the hub and screw bolts into the holes. Turn central screw puller, remove pulley hub with the cone of the camshaft. Remove toothed belt tensioner.
| Fig. 3.3.57. Location studs (1) and bolts (2-4) securing the rear toothed belt
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Remove the bolts 2-4 (Fig. 3.3.57) fastening the rear casing of a gear belt. Screwing on pin 1 (see. Fig. 3.3.57), two nuts, remove it from the cylinder head.
| Fig. 3.3.43. Sequence of a tightening of bolts fastening the cylinder head cover and place the crankcase ventilation hose connection
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Disconnect the crankcase ventilation hose from the cylinder head cover (see. Fig. 3.3.43). In sequence, return to a tightening, loosen the screws cylinder head cover (see. Fig. 3.3.43) and remove it.
| Fig. 3.3.60. Sequence of a tightening of bolts of the cylinder head
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In the reverse tightening gradually loosen and then completely unscrew the bolts of the cylinder head (see. Fig. 3.3.60). 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 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. 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.
The protrusion of the pistons, mm | Number of holes | 0,91-1,00 | 1 | 1,01-1,10 | 2 | 1,11-1,20 | 3 |
| Fig. 3.3.58. The arrangement of cams of a camshaft, the first cylinder control valves, during installation of first cylinder to TDC in the compression stroke
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Before installing the cylinder head and crank set the camshafts to a position corresponding to the TDC of the first cylinder. Cams camshaft control valves of the first cylinder shall be directed upwards (Fig. 3.3.58).
| Fig. 3.3.38. Fixing the toothed belt pulley of the crankshaft a special tool T10050: 1 - pointer to the device T100500; 2 - label on a pulley
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Install special tool T10050 toothed belt pulley of the crankshaft 1 (see. Fig. 3.3.38), and the label on a pulley 2 should be combined with the index on the device. When installing the device T10050 its projection shall enter into the groove of the cylinder.
| Fig. 3.3.59. Marking gasket cylinder head cover: 1 - the number of pads; 2 - code; 3 - holes that determine the thickness of the lining
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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 the value of the selected thickness of the new cylinder head gasket (Fig. 3.3.59). 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, and then in the sequence shown in Fig. 3.3.60, in four steps: Stage 1 - 40 Nm; Stage 2 - 60 Nm; Stage 3 - tighten on a corner 90 ?�; Step 4 - tighten on a corner 90 ?�. Additional tightening the cylinder head bolts after the engine warms up, or after a certain time is required. Install the pulley hub gear belt on the cone of the camshaft. Replace and tighten the bolt of a pulley hub torque of 100 Nm, while the device T10051 hold the hub from turning (see. Fig. 3.3.55). Install toothed belt pulley on the hub and tighten the pulley bolt. Install a locking pin 3359 or drill shank 6 mm in diameter into the hole and secure the camshaft pulley from turning. Install the timing belt. Install the cylinder head cover. Install poly V-belt. Install the front cross bar to its normal position. Check that the exhaust systems are properly installed on the suspension and do not touch the body with shaking. Check the engine oil level. Fill the cooling system with fresh 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 click on all window switches again for at least 1, in the closed position of the control unit to activate windows. Set the clock. Before starting the engine again and check that the engine oil level. After separation of the various electrical connections in the memory control unit writes error information to be erased after installation. Adjust headlights.
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