Removal and installation of the cylinder head

Cylinder heads are allowed to shoot only on the cold engine. The cylinder head is removed along with the exhaust manifold, while the intake manifold must be disconnected before removing the head. New gaskets for cylinder heads are packed in plastic, so the package should be removed just prior to installing the gasket. Removal and installation of the cylinder head can be performed without removing the engine from the car. When removing and installing camshaft specify further details on the timing of the engine set out in the relevant section. This avoids repetition of description necessary for this work. In each case, the scope of work is determined by the vehicle equipment. Removing the cylinder head must be carried out in the following sequence:

- Disconnect the "mass" wire from the battery;

- Drain the coolant from the cooling system;

- Remove the radiator grille and the crossbeam in order to provide better access to parts of the engine;

- Notching the mounting clamps that hold the wiring harness of the engine;

- Remove the drive belt from the end of the engine. In Fig. 23 shows that the belt tensioner. Bolt 1 2 damper mechanism keeps the tension. For removal of the belt is necessary to turn the nut on the flange of the insert mandrel (diameter 12 mm and length 180 mm) in the opening lever spring tension indicated by an arrow. With this mandrel take tensioner left (Fig. 24). Unload the hex bolt to such an extent that you can unscrew the bolt, and then slowly release the mandrel so that the tension spring is moved in the direction of the intake manifold, and could be removed. Remove the bolt 1 damper 2 (see. Fig. 23) of the belt tensioner of the cylinder head (Fig. 25) and remove the fasteners (see. The further description). Then remove ribbed belt;

- Loosen the hose clamps of the cooling system and disconnect the wire from the coolant temperature sensor;

- Disconnect the linkage motor control;

- Detach vacuum line from the vacuum pump. Remove the hose and loosen the union nut;

- To link the fuel suitable clamp and remove them from the fuel filter or to remove the fuel filter and put it aside in order not to interfere in the process.

On the four-cylinder engine

Remove the fuel high pressure first, second and third cylinders together with the fastening element, and the fourth cylinder fuel - without fastening.

In the five-cylinder engine

High pressure pipelines fourth and fifth cylinders being held by two plastic clips. Remove the fuel return line from the nozzle of the first cylinder. To eliminate the dirt is necessary to close its hole (for example, a bolt of suitable diameter);

- Disconnect from the intake manifold damper speed control. It is within the specified on Fig. 26 place;

- Disconnect the vacuum hose from the thermo-valve;

- Disconnect the wires from the glow plugs;

- Disconnect from the intake manifold protective box wiring and pull it forward;

- Disconnect from the oil filter mounting supply pipe heating system;

- To disconnect a reception pipe flange on the exhaust manifold, and a clamp reception pipe from the gearbox;

- Remove the duct connecting the air filter to the intake manifold;

- Remove the intake manifold;

- Remove the cylinder head cover. It is secured by six bolts on the upper side of the engine. Pre remove hose crankcase ventilation. On vehicles with automatic transmission, you must first disconnect the fuel control rod, which passes over the cylinder head cover;

- Remove the viscous coupling, bolted to the end face of the engine (viscous coupling can not be put on the impeller can be placed only on the side);

- Unscrew the injector fuel injection system (Fig. 27) and remove the O-rings under them;

- Turn the engine before the installation of the piston of the first cylinder in the TDC, it is necessary to combine adjusting labels shown in Fig. 28. To turn the engine can use a replaceable face head size of 27 mm mounted on the pulley nut and ratchet knob. Crankshaft must rotate only in the direction of working rotation;

- Remove the chain tensioner (see. The appropriate Div.). Unscrew the nut of the tensioner, using a large hexagon. This nut is located above the water pump and the thermostat cover;

- Camshaft drive sprocket and drive chain should mark each other. To do this, apply two strips of paint on the camshaft drive sprocket and drive chain, as shown in Fig. 29;

- Release screws on camshaft sprocket drive. To prevent rotation of the camshaft sprocket lock the drive shaft with a large screwdriver or a bolt, as shown in Fig. 30;

- Carefully dismantle the star with the camshaft, without letting the drive chain to withdraw from the engagement with the crankshaft sprocket. This means that the chain should be kept constantly under tension and be appropriately sling;

- Remove the camshaft as described in Section. 2.12.6. Evenly loosen the fastening bolts of covers of bearings;

- Remove the pacifier chain with the cylinder head (Sect. 2.12.4);

- Now it is possible to unscrew the cylinder head bolts. To prevent deformation of her head bolts must be loosened in the reverse sequence shown in Fig. 31 and 32. For the loosening of these bolts need a so-called a polygonal insert the key. The specification of the company Mercedes-Benz, he was listed at number 601 589 00 10 00. The use of a conventional plug-in hex wrench can damage the screw heads. Do not forget to turn on the crankcase circuit two small bolts that are shown in the lower part of Fig. 32. Of these bolts often overlooked. Immediately after the loosening of all bolts must measure their length from the lower edge of the bolt head to the end of the threaded portion in order to determine the degree of their elongation. If the results of the measurements show that the length of bolts, depending on the installation location exceed 83.6; 105.6 and 118.5 mm, these bolts must be replaced, the size of which is 80; 102 and 115 mm. Tighten the bolts must be in the reverse order;

- In the upper part of the crankcase chain loosen the two bolts with M8 hexagon socket head (shown at the bottom of Fig. 32). Number of plug-in hex wrench 8 mm. In order to get close to these screws, you must use an extension cord for the above key;

- Remove the cylinder head. To facilitate this work, you can use the lifter, securing the head of the lifting lugs;

- After removal of the cylinder head gasket surface thoroughly clean the head and the cylinder. If you want to repair the cylinder head according to the instructions in Section. 2.4.3;

- If necessary, replace only the head gasket must be installed on the engine;

- On the surface of the connector to put a new cylinder head gasket;

- Set the cylinder head, making sure that the guide sleeve sat on their seats. They are located on the same side;

- Lubricate the threaded part and the place fit bolts of the cylinder head. This is done after measuring the length of screws and bolts of replacement overly stretched out.

Installation and initial bolts the moment of 15 Nm must be carried out in the sequence shown in Fig. 31 and 32. Then, in the same sequence all screws are stretched to 35 Nm and then to pause of 10 minutes. Mounting the cylinder head bolts are of different lengths, so must be installed in strict accordance with the label and length.

After a pause to tighten on 90 ?� each bolt in the same sequence. To perform this operation it is not necessary to use a torque wrench.

After all this, the bolts of the cylinder head again to tighten on 90 ?�, since the bolt 1, subject to the specified sequence.

Two bolts with hexagon socket head plug M8 shown in the lower part of Fig. 32, must be tightened to 25 Nm. When you reach a certain mileage of the vehicle in a subsequent broaching fasteners cylinder head is no longer necessary. Such a requirement existed previously for other types of vehicles;

- To establish the chain damper on the cylinder head;

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- Put on the camshaft drive sprocket together with the chain, drawing attention to the fact to make paint marks are aligned (see Fig. 29), and planting coincided with the pin shaft hole in the sprocket. At the top of Fig. 33 shows where to check the pin engages the landing;

- Tighten to 45 Nm mounting bolt of an asterisk of a camshaft drive, keeping it from turning using a large screwdriver or a bolt, as shown in Fig. 30;

- Install chain tensioner, tightening it to a torque of 80 Nm;

- Verify that the markings on the camshaft in the position of the piston of the first cylinder of the TDC. On the camshaft has a label, which is in finding the piston of the first cylinder in the TDC should be cast against the arrow on the bearing cover. This arrangement labels shown in the lower part of Fig. 33;

- Connect the wiring to the glow plugs;

- Install the intake manifold;

- Connect the fuel to the injectors;

- Attach the exhaust pipe to the exhaust manifold;

- Install the fuel filter and fuel lines connected to it;

- Set the drive belt tensioner, performing all operations in sequence, return dismantling;

- Set the cylinder head cover;

- Connect the temperature sensor to output in the instrument cluster.

All other work is done in the reverse order of removal.