Removing
The cylinder head is removed only from a cooled engine. The inlet pipeline and an exhaust manifold can not be disconnected.
Cylinder Head Assembly Components
1 - Cylinder head
2 - Camshaft
3 - Camshaft bearing cap
4 - Eye
5 - Hairpin
6 - Hairpin
7 - Cover
8 — an epiploon of a camshaft
9 - Valve
10 - The lower plate of the valve spring
11 - Oil deflector cap
12 - Valve spring
13 - The upper plate of the valve spring
14 - Rusks
15 - Valve lifter
16 - Adjusting washer
1. Disconnect the negative cable from the battery.
2. Remove the cap from the expansion tank of the cooling system, thereby relieving pressure in the system.
3. Remove the air filter and air supply hose.
4. Drain the coolant (see chapter Vehicle settings and routine maintenance).
5. On turbodiesel Turn out bolts of fastening and remove the holder of soaking-up pipe and pipes of forced air on a head and the block of cylinders. Remove the dipstick guide tube from the engine block.
Close the open connection flanges on the turbocharger
6. Remove the toothed belt from the gears of the injection pump and camshaft (see Section Removing and installing timing belt).
7. Turn out bolts of fastening of a cogwheel of a camshaft. Remove the TDC position retaining bolt from the camshaft sprocket and remove the camshaft sprocket
Bolts of fastening of a cogwheel of a camshaft
8. Turn out the top bolts of fastening of a back cover of a gear belt.
9. Turn out bolts of fastening and remove a reception pipe of system of release from a collector and from the holder on an intermediate flange, on turbodiesel - from the connecting pipe of the turbocharger.
10. Remove the mounting bolts and remove the heat shield from the exhaust manifold.
11. On turbodiesel unscrew the hollow bolt of the pressure oil line on the turbocharger.
12. Remove the fuel lines from the injectors and from the injection pump without changing their shape.
13. Remove the hose from the fuel return line.
14. Disconnect the wiring harness from the intake manifold.
15. On turbodiesel remove the pressure hose from the inlet pipeline.
16. Disconnect the electrical wiring of the contact bus of the glow plugs.
17. Separate a socket Д/B of temperature of a cooling liquid and the sensor of temperature.
18. Disconnect the cooling system hoses from the thermostat housing.
19. On naturally aspirated engine Disconnect the coolant pipe from the outlet pipe. On turbodiesel wring out a connecting branch pipe of the lower hose of system of cooling from a pipe.
20. Give bolts of fastening of a head of cylinders outside inside at first on a quarter, and then on a half-turn. Then completely turn out the bolts.
Order of giving of bolts of fastening of a head of cylinders
Remove bolts only when the engine is cold.
21. Press a little aside a back cover of a gear belt and lift a head of cylinders with the inlet pipeline and a final collector.
A description of the procedure for disassembling the cylinder head, if it is necessary to carry out its refurbishment, is given in Part General and overhaul of the engine of this chapter.
Preparing for installation
1. Thoroughly clean and dry the mating surfaces of the head and cylinder block. Use a hard plastic or wood scraper to remove all traces of old gasket material and carbon deposits. Also clean the piston bottoms. Be extremely careful - surfaces are easily damaged. Remember that dirt should not get into the oil channels, water galleries, channels and threaded holes - plug them with plugs or seal them with tape. To prevent deposits from getting into the gaps between the pistons and cylinders, fill the last with a thick lubricant, which, after cleaning, can be easily removed with a stiff brush. After cleaning, wipe all surfaces with a clean, dry cloth.
2. Inspect the mating surfaces of the head and block for deep scratches, cracks, or other damage. Minor defects can be eliminated with a small scraper, in more serious cases, the head should be machined or replaced.
3. Make sure the threaded holes are clean and dry - just in case, blow them out with compressed air (you can use a bicycle pump). The presence of traces of grease in the blind holes can lead to the destruction of the block when the bolts are tightened as a result of the increase in hydraulic pressure.
4. Head bolts must be replaced without fail, regardless of their current condition.
5. Using a steel ruler and a blade-type feeler gauge, check the flatness of the mating surface of the head (see part General and overhaul of the engine this chapter).
6. On these engines, the gap between the head and the pistons is controlled by the thickness of the gasket. As markings, the narrow side of the gasket has two or one hole, or there may be no holes.
7. If the cylinder head or block has been machined or new pistons installed, the gasket thickness must be determined again. To do this, using an indicator at three points of the piston, the value of its excess is measured. First remove the residues of combustion products on the piston crown and cylinder block.
Measuring piston protrusion on 1.7L SOHC engines
If, when measuring piston protrusion, one of the 12 values exceeds the upper limit of the corresponding range by 0.05 mm, the next thickness class must be selected.
Cylinder head gasket
Designation |
Thickness, mm |
When the piston protrudes, mm |
without hole
|
1,35
|
0.58 ÷ 0.64
|
1 hole
|
1,40
|
0.65 ÷ 0.70
|
2 holes
|
1,45
|
0.71 ÷ 0.78
|
Installation
Replacing the cylinder head bolts is mandatory, regardless of their current condition!
1. Lay a new gasket without sealant on the grease-free mating surface so as not to block the holes. Inscription «OBEN/TOP» The gasket must face up and towards the engine timing belt.
2. Install the cylinder head.
In this case, none of the pistons should be in the TDC position. To do this, first turn the crankshaft forward or backward a quarter of a turn.
3. Install new cylinder head bolts evenly in reverse order indicated in the illustration.
Be sure to use new bolts. The bolts must be tightened in three steps: first with a force of 40 Nm, then twice at an angle of 60 ÷ 75 degrees.
4. Install the cylinder head cover with a new gasket and tighten its fasteners crosswise with force 8 Nm.
5. Installation is carried out in the reverse order to the dismantling of the components. Tighten fasteners to the required torque. Use new seals when installing the dipstick guide tube, turbocharger hoses, exhaust pipe.
6. At the end of the installation, fill the cooling system and check and, if necessary, correct the oil level in the engine. If the engine was removed due to damage to the cylinder head gasket, change the oil and oil filter, as There may be coolant in the engine oil.
7. Check and, if necessary, adjust the idle speed and maximum speed.
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