Attention.
- Hot engine and oil can cause burns. Be careful not to burn yourself when removing/installing various components.
- Fuel vapors are dangerous. They are highly flammable, causing serious injury and equipment damage. Keep sparks or open flames away from fuel.
- Leaks and leaks in fuel lines are dangerous. Fuel can ignite and cause equipment damage, serious injury or even death. Fuel can cause skin and eye irritation. To prevent this, observe the safety regulations when handling fuels and lubricants.
Removing the cylinder head
1. Disconnect the negative battery terminal.
2. Remove the decorative engine cover.
3. Remove the fuel injectors.
4. Remove the front protective tray No. 2 of the engine.
5. Remove the right mudguard.
6. Remove the attachment drive belt.
7. Drain engine oil.
8. Drain coolant.
9. Disconnect the upper radiator hose.
10. Remove intake manifold.
11. Disconnect the catalytic converter from the middle exhaust pipe and remove the catalytic converter.
12. Remove the turbocharger.
13. Remove the lower housing from the engine.
14. Remove the vacuum pump.
15. Remove the supply fuel pump.
16. Remove the camshaft position sensor.
17. Disconnect the heater hose.
18. Remove the oil pan.
19. Remove the timing chain with damper (see relevant section earlier in this chapter).
1. Camshafts.
2. Rocker arms.
3. Cylinder head.
4. Laying of a head of the block of cylinders.
Note:
: replace the part with a new one after each removal.
: apply oil.
20. Unscrew the bolts securing the camshaft covers in several approaches in the sequence shown in the figure, and remove the camshaft covers.
21. Remove camshafts.
22. Remove the rocker arms from the cylinder head and lay them out in order for installation in their places during subsequent assembly.
23. To remove a branch pipe of system of cooling shown in drawing.
Note: : replace the part with a new one after each removal.
24. Temporarily install an oil pan to support the engine from under the vehicle.
Attention. To prevent deformation of the oil pan, support the engine as follows:
- When using an engine jack, place a piece of rubber of a suitable size (about 20 mm thick) between lift and oil pan.
- When using a garage jack, place a piece of rubber of a suitable size (about 20 mm thick) on the base plate resting on the oil pan.
25. Support the engine (oil pan) a special engine lift or a garage jack.
26. Remove fixture 49 L017 5A0, on which the engine was hung, and put aside.
27. To turn away bolts of a head of the block of cylinders in two or three approaches in the sequence specified in drawing.
28. Remove the cylinder head.
29. Remove the cylinder head gasket and replace it with a new one.
Installing the cylinder head
1. Thoroughly clean the contact surfaces of the cylinder block and block head.
2. Install a new cylinder head gasket
3. Install the cylinder head on the engine.
Attention. If length (L) cylinder head bolt exceeds the limit (170.5 mm), you need to replace it with a new one.
4. If cylinder head bolts are reused, apply engine oil to their seating surfaces.
5. Tighten the cylinder head bolts in the sequence shown in the figure in five stages:
- Stage 1: 13-17 Nm.
- Stage 2: 36-40 Nm.
- Stage 3: 85-95°.
- Stage 4: 85-95°.
- Stage 5: 85-95°.
6. Install the traverse again and hang the engine.
7. Remove the engine jack or garage jack.
8. Remove the temporarily installed oil pan.
9. Apply engine oil to the hydraulic lifters and the ends of the valve stems, then set the rocker arms to their original positions, which they occupied before removal.
Note: apply oil.
10. Apply gear oil (SAE 90 or similar) or engine oil on the following areas:
- Each support in the cylinder head.
- Needle bearings and rocker contact surfaces.
Note: : apply oil.
11. Apply gear oil (SAE 90 or similar) or engine oil on the following surfaces of each camshaft:
- Gear contact surfaces.
- Thrust surfaces of the anterior neck.
Note: When applying oil to the front camshaft cover, do not apply oil to the thrust surface of the front camshaft journal.
12. Place the camshafts in the cylinder head and align the gear alignment marks as shown.
13. Apply gear oil (SAE No. 90 or similar) or engine oil on the center of each camshaft journal as shown.
Note: : apply oil.
14. Apply adhesive (Loctite 962T) on the rear side of the cylinder head or on the rear camshaft cover.
Attention.
- Make sure that the adhesive does not get on the camshaft journal.
- To prevent premature curing of the adhesive, install the rear camshaft cover and cylinder head within 10 minutes of application. Tighten the fastening bolts immediately.
Note: Adhesive bead width: 1.0-3.0 mm.
15. Apply engine oil to a new O-ring and install it in the rear camshaft cover.
Attention. Be careful not to damage or drop the O-ring when installing the rear camshaft cover.
16. Apply gear oil (SAE 90 or similar) or engine oil on the thrust surface of the front camshaft cover.
Note: If oil is applied to the thrust surface of the front journal of each camshaft, it is not necessary to apply oil to the front cover of the camshafts.
17. Install the camshaft covers in numerical order (according to the markings on the lids) and evenly screw on the cover bolts in two or three passes in the sequence shown in the figure.
18. Tighten the camshaft cover bolts in two stages in the sequence shown in the figure:
- Stage 1: 3.0-6.0 Nm.
- Stage 2: 8-11 Nm.
19. Install the remaining engine components in the reverse order of removal.
20. Fill in the required amount of engine oil of the correct grade (see chapter 8 "Lubrication system").
21. Fill with coolant.
22. Start the engine and check the following:
- Leaks in engine oil and coolant.
- Engine oil level in the engine.
- Beating and touching of pulleys and belts.
- Idle speed.
- Compression in the cylinders.