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Cylinder Head
The cylinder head of the engine 1,8-I
1 - oil filler cap,
2 - the nut of the cylinder head cover 10 Nm
3 - the cylinder head cover,
4 - a lining. When installing the gasket, apply to the surface of a thin layer of sealant D2.
5 - Oil deflector,
6 - cylinder head,
7 - the intake manifold gasket. When installing, only use a new gasket. | 8 - cylinder head gasket. When installing, only use a new gasket. After installation of the cylinder head must be filled with fresh coolant.
9 - a bolt of fastening of a tension roller 25 Nm
10 - the exhaust manifold gasket. When installing a new gasket.
11 - bolts of the cylinder head. When installing, use only new bolts.
12 - thermofilter,
13 - screw, 25 Nm
14 - the screw 10 Nm. |
This section sets out the operation to remove the cylinder head on the four-cylinder petrol engine 1,6-I and 1,8-I.
A warning  Before removing the cylinder head, check that all hoses, pipes and electric sockets are disconnected from the cylinder head.
Removing the cylinder head engine cold. Removal of the cylinder head is made together with the exhaust manifold. At the same time the intake manifold must first be removed from the cylinder head. Burned or defective cylinder head gasket is determined by the following features: - Reduction of engine power;
- Reduction of the coolant level. At the same time from the exhaust pipe goes white steam;
- Reducing the level of engine oil;
- The presence of oil in the engine coolant. The level of oil increases. In the presence of engine oil in the engine oil coolant becomes gray and has a foam bubbles;
- The presence of engine oil in the coolant;
- Intense release of bubbles from the cooling liquid;
- A reduction in the compression of two adjacent cylinders of the engine.
Withdrawal
Location bolts on the inlet manifold on the engine 125 hp. from.
Sequence of loosening bolts of the cylinder head
| PERFORMANCE ORDER | | 1. Check that the engine is cold. Otherwise, let the time to cool the engine. | | 2. Turn off the ignition and remove a wire of weight from the accumulator. | | 3. Drain the cooling system of the engine coolant. | | 4. Mark the high-voltage wires in figures and remove high-voltage wires from spark plugs. | | 5. Clear candles, using a brush, vacuum cleaner or a jet of compressed air that will exclude dirt hit in cylinders of the engine after removing the spark plugs. Remove the spark plug using the spark plug spanner. | | 6. Remove the pressure in the fuel system. To relieve the pressure in the fuel system, wrap the connection of fuel hoses and, being careful, slowly loosen the connection, while gradually the fuel pressure decrease. | | 7. Mark and disconnect submitting and returnable fuel hoses from the fuel distributor. Before you disconnect hoses tion loosen the clamp and slide it over the hose. | | 8. After disconnecting close the ends of pipelines suitable stoppers. | | 9. Disconnect electric sockets from fuel atomizers and move the fuel line down. Mark and disconnect from the cylinder head all the electrical connectors. | | 10. Remove the cylinder head from the bracket that supports the intake manifold around the fuel pressure regulator. | | 11. Remove the intake manifold from the cylinder head, see. Fig. Arrangement of bolts of fastening of the intake manifold on the engine 125 hp. | | 12. Remove the intake manifold from the two rubber mounts and move away from the cylinder head. | | 13. Mark and disconnect from the cylinder head cooling system hoses. | | 14. Remove a reception exhaust pipe with catalytic converter from the exhaust manifold. | | 15. Remove the top casing of a gear belt. For bolt crankshaft pulley cranked shaft of the engine clockwise before combination of adjusting labels on pulleys of a pointer. Wherein the first cylinder is located in the TDC in the compression stroke. | 16. Using a paint or marker, mark the position of the crankshaft pulley with respect to the cylinder block and turn the crankshaft by 90 ?� clockwise so that none of the piston is at the top dead center.
Before installation of the toothed belt establish crankshaft in a position in which the first cylinder piston is at TDC in the compression stroke. | | 17. In the sequence shown in fig. Sequence of loosening the bolts of the cylinder head, slowly and evenly loosen the bolts of the cylinder head. | | 18. Make sure that on the cylinder head and disconnect pipes, hoses and electrical connectors. | | 19. Remove the cylinder head from the engine and install it on two pieces of wood. | | 20. Remove the cylinder head gasket. |
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Preparation for the installation of the head
Place measuring the height of the cylinder head | A = 139.2 mm for the 1.8-liter engine A = 132.6 mm for the 1.6-liter engine
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| PERFORMANCE ORDER | | 1. Remove the plastic plugs for protecting the open valve cylinder head. | 2. The mating surface of the cylinder head and must be perfectly clean. For their clearing use a firm plastic or wooden scraper.
A warning When cleaning, be careful, as the aluminum alloy is very easily damaged.
| | 3. 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. | 4. Check the mating surfaces of the cylinder head and the presence of notches, deep scratches and other damage. If the defects are small, they can be removed by machining.
A warning The height of the cylinder head after machining should be the engine of 1,8 l = 139.2 mm, and for the engine of 1,6 l = 132.6 mm.
|  | 5. Using a metal ruler and a feeler gauge, check the flatness of the mating surfaces.
Deviation from the flatness should be less than 0.1 mm. | 6. Clean the bolt holes in the engine block. Tightening the screws in the aperture filled with oil can break off the block because of hydraulic pressure.
A warning When installing the cylinder head is necessary to use new bolts of the cylinder head and a new cylinder head gasket.
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Setting
Places screwed guide pins VW-3070 VW-3450 or in the engine block
Sequence of a tightening of bolts of the cylinder head on the four-cylinder engines
Places D2 sealant application before installing the gasket cylinder head cover
| PERFORMANCE ORDER | 1. For the proper installation of the cylinder head and cylinder head gasket screw hole in the extreme cylinder intended for the bolts of the cylinder head, guide pins VW-3070 (engine AHL VW-3450). In the absence of the guide pins can be made independently, which requires the use of two old bolts of the cylinder head. Cut off from the bolt head and instead cut the groove for screwdriver. After installation of the cylinder head, using a screwdriver, unscrew the guide pins, see. Fig. Designated screwed guide pins VW-3070 VW-3450 or in the engine block.
A warning When installing the cylinder head is necessary to use a new gasket. Remove the liner from the hermetic package immediately prior to installation on the cylinder block.
| | 2. Check that the new cylinder head gasket has the same type as the original, and that the marking or OBEN TOP points upwards. Place new cylinder head gasket on the surface of the cylinder to the guide pins. Check that the holes are aligned properly with the TV system of cooling and lubrication. | | 3. Carefully set the head on the block. | | 4. Insert and hand-tighten the 8 bolts and washers securing the cylinder head. | | 5. Use a screwdriver to remove the two guide pins in their place and screw the two mounting bolts of the cylinder head. | 6. Gradually, in the sequence shown in fig. Sequence of a tightening of bolts of the cylinder head on the four-cylinder engines, in several stages, tighten the bolts of the cylinder head.
A warning Do not tighten the bolts of the cylinder head to the engine is warm. When installing a new cylinder head with the camshaft after installation of the cylinder head grease with a thin layer of grease the mating surfaces of hydraulic tappets and camshaft cams.
| | 7. cranked and distribute tional shafts in a position to conform to the installation of the piston of the first cylinder at TDC on the compression stroke. | | 8. Before installing the inner liner cylinder head cover lubricate the surface mating with seal, with a thin layer of sealant D2 (see. Fig. Designated D2 sealant application before installing the gasket cylinder head cover). Place the gasket cylinder head cover. | | 9. Install the cylinder head cover and gradually and consistently wise tighten cover nuts. | | 10. Establish a gear belt on a pulley of a camshaft and adjust its tension. | | 11. Screw the reception exhaust pipe. | | 12. Install the intake manifold with a new gasket on the cylinder head and fix its bolts, having tightened their demanded moment. | | 13. Screw the lower part of the intake manifold to the rubber mounts. | | 14. Establish an arm between the cylinder head and intake manifold. | | 15. Attach the supply and return fuel lines to the fuel line. | | 16. In accordance with the previously made marks, connect the cylinder head all the electrical connectors. | | 17. Install the timing belt covers. | | 18. Check that all hoses, pipes and electrical connectors are connected according to earlier made marks. | | 19. Check the engine oil level and, if necessary, finish it to norm. If the old cylinder head gaskets were defective, replace engine oil. | | 20. Fill in cooling liquid in cooling system. | | 21. Fill in cooling liquid in cooling system. | | 22. Connect the ground cable to the battery. | | 23. Start the engine and warm it up to normal operating temperature. Turn off the engine and check the engine oil and coolant, and the tightness of all connections. |
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