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Removal and installation of the cylinder head
Withdrawal Disconnect the ground cable from the battery when the ignition is off. Remove the engine cover.
Unscrew the screw A, pull the air filter upwards from the attachment (Fig. 2.253). Remove the air filter housing with mass flow sensor and connection tube. Remove the battery. Remove the soundproofing screen. Drain the coolant. Remove the reverse and the fuel supply line and the cooling tube from the cylinder head. Before removing the cylinder head to pump fuel with a manual vacuum pump with accessories and the capacity to pump fluid from the tandem pump. Remove ribbed belt. Remove the connecting hose intercooler / intake pipe.
| Fig. 2.294. The combination of labels on a cover of a gear belt and cam-shaft
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Remove vibration damper and remove it from the crankshaft. Secure crankshaft with special tool or lock the crankshaft crankshaft at TDC of the first cylinder (Fig. 2.294).
Vehicles without particle filter Remove the exhaust pipe from the turbocharger, remove the clamp and remove the double exhaust pipe.
Vehicles with particulate filter Remove the particle filter.
Continuation for all vehicles Remove the support and the turbocharger oil return pipe from the turbocharger. Unscrew the fixing nut of a tension roller and loosen the tension of the toothed belt. Remove the retaining nut of a tension roller. Remove the camshaft gear and hub. Remove the hall sensor on the cylinder head. Remove the fixing bolts bottom of the cover of a gear belt on the cylinder head. Remove the holder vacuum receiver and the dipstick. Remove the connecting pipe for exhaust gas recirculation. Remove the feed oil highway turbocharger. Remove / disable all other existing electric wires from the cylinder head. Disconnect the cylinder head all connection, vacuum inlet hoses and hoses and coolant. Remove the cylinder head cover. Remove the axis of the roller levers and internal mounting screws of the module supports.
| Fig. 2.302. Sequence of loosening the bolts of the cylinder head
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Observe sequence when loosening bolts of the cylinder head (Fig. 2.302). Slightly lift and remove the cylinder head from the engine by a protective cover of a gear belt.
NOTE Tensioner toothed belt remains on the motor support. Keep the cylinder head must be very careful in order to avoid damage. |
Setting Apply marking up the cylinder head gasket.
NOTE Always replace the cylinder head bolts. When repairing, remove the cylinder head and cylinder block of sealant residues. Prevent formation of long scratches or scuffing. When using sandpaper grit it should not be less than 100. Remove the remaining emery and polishing. A new cylinder head gasket must be removed from the packaging directly before installation. Damage to the silicone layer and single-convolution connections lead to a loss of tightness. Before installing the cylinder head, crankshaft, remove the lock or lock the crankshaft and rotate crankshaft against the direction of rotation of the engine until all the pistons will not stand uniformly lower TDC.
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For centering screw guide bolt into the outer holes on the suction side (Fig. 2.303).
NOTE When installing the cylinder head tensioning pulley must be installed on the stud bolt. |
Install the cylinder head, insert the remaining 8 cylinder head bolts and tighten them by hand. Remove the guide bolt with a screwdriver through the hole and install the cylinder head bolts. Then tighten the cylinder head bolts in 4 stages as follows: 1 - tighten torque wrench; - Stage 1 = 35 Nm; - Phase 2 = 60 Nm; 2 - then turn the conventional key; - Stage 3 = tighten 1/4 turn (90 ?�); - Phase 4 = tighten 1/4 turn (90 ?�). Fix the lower portion of the toothed belt on the cylinder head.
| Fig. 2.304. Sequence zaruchivaniya bolts of the cylinder head
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Screw the Hall sensor on the cylinder head. Install the hub and the camshaft gears. Secure camshafts with locking pin for diesel injection pump
Rotate the crankshaft in the direction of rotation of the motor shaft and insert it into the TDC position, lock the crankshaft using the crankshaft lock or lock the crankshaft (Fig. 2.301). Center the camshaft gear in the longitudinal grooves. Apply the toothed belt first on the exhaust camshaft gear, then the gear on the intake camshaft. Install the fixing nut of a tension roller.
| Fig. 2.298. The correctness of landing a tension roller
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NOTE Watch out for the correct tensioning pulley landing in the back of the timing belt cover (Fig. 2.298). |
Then rotate the tensioning roller using a wrench in the direction of the arrow until the arrow is in the middle period of the base plate (Fig. 2.299). Make sure that it does not rotate the fixing nut. Fix the tensioner roller in this position and tighten the fixing nut of the tensioner roller, as follows, 20 N ?� m and tighten by 45 ?� (1/8 turn).
Install the counter support, as shown in Figure 2.300. Click on the counter support in the direction of the arrow and tighten the camshaft gears. Tighten mounting bolts camshaft gear in this position with a torque of 25 Nm. Remove the locking pins, latch or lock the crankshaft crankshaft. Take a minute. 2 revolutions of the crankshaft in the direction of rotation of the motor shaft and reinstall the first cylinder to the top dead center position.
Lock hub A in the direction of rotation of the motor shaft with a locking pin (Fig. 2.296). Check that the hub was fixed with a locking pin. The crankshaft has been fixed with the clamper crankshaft. Arrow tensioning pulley should be located in the middle or max. 5 mm gap to the right of the support plate. Further installation in reverse order. It is necessary to consider the following. Install axle roller levers. Install the cylinder head cover. Install the oil feed pipe. Install poly V-belt. Fill in cooling liquid. Perform a test drive and interrogate fault memory.
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