Engines E1, E3, E5
1 - cylinder head cover; 2 - a bolt of fastening of a cogwheel of a camshaft; 3 - camshaft drive chain; 4 - camshaft; 5 - bolt; 6 - segment seal; 7 - cylinder head; 8 - spark plug; 9 - valve; 10 - rocker shaft with rocker arms and camshaft bearing halves; 11 - cylinder head bolt; 12 - cylinder head cover gasket
In principle, the cylinder head of E engines is of the same design as other gasoline engines. The following text will only point out the differences.
Removing
1. Disconnect the ground cable from the battery.
Attention! This erases the data from the engine fault memory or the radio's security code. Before disconnecting the battery, read the instructions in Section Removing and installing the battery.
2. Block the crankshaft and unscrew the bolt securing the camshaft gear.
3. To block the crankshaft, turn on the 5th or 4th gear and ask an assistant to depress the brake pedal.
4. Unscrew the drive chain tensioner.
5. Loosen the cylinder head bolts in sequence 1 to 10 in the first pass by 1/2 turn, in the second pass by one full turn, and back out completely on the third pass.
Attention! Loosening the cylinder head bolts in the wrong order can result in deformation or cracks in the cylinder head.
6. Remove the rocker shafts with the halves of the camshaft bearings.
7. Tie the camshaft sprocket and drive chain with wire to fix the position of the sprocket and chain relative to each other.
8. Remove the camshaft sprocket and remove the camshaft.
9. Ask an assistant to keep the camshaft sprocket under tension at all times so that the drive chain does not come off the crankshaft sprocket.
Attention! If the chain has come off the crankshaft sprocket, the timing gear needs to be adjusted again.
10. Check that all hoses and wires from the cylinder head to the engine and body are disconnected.
11. Remove the cylinder head with the help of an assistant.
Attention! Do not place the cylinder head on the sealing surface after removal, otherwise fully open valves may be damaged. Lay the cylinder head on two wooden blocks.
Installation
1. Insert the camshaft.
2. Install the camshaft sprocket with drive chain.
3. Install rocker shafts with camshaft bearing halves.
4. Screw in 10 bolts until they touch the cylinder head by hand. Then the bolts should be tightened in three passes. On each pass, the bolts are tightened in sequence, from 1st to 10th.
- 1st pass: 50 Nm
- 2nd pass: 70 Nm
- 3rd pass: 90 Nm
Attention! Cylinder head bolts must be tightened very carefully. Before tightening, check the accuracy of the torque wrench. In addition, the tightening sequence must be followed exactly.
5. Block the crankshaft, install the camshaft gear bolt and tighten it with force 75 Nm.
6. To block the crankshaft, turn on the 4th or 5th gear and ask the assistant to depress the brake pedal.
7. Press the stopper in the direction of the arrow and fully push the chain tensioner sleeve into the tensioner housing. Fasten the coupling with a bracket.
8. Install and screw the chain tensioner with a new gasket.
9. After installing the tensioner, the bracket is loosened by rotating the crankshaft. The clutch moves automatically and sets the chain play.
10. Check drive chain adjustment. To do this, turn the crankshaft so that the mark on the belt pulley coincides with the mark "T". At the same time, the rocker arms of the 1st cylinder should have a small play, and the rocker arms of the 4th cylinder should be in the valve overlap position, i.e. both valves should be pressed with the rocker arms down. If this is not the case, the drive chain needs to be adjusted again.
11. Install the cylinder head cover with a new cover gasket and segment seal. Screw the cover firmly 10 Nm.
12. Connect the battery ground cable.
13. If available, set the clock and set the radio security code.
14. Check valve clearance, see Section Checking/adjusting valve clearance.
Drive chain adjustment
1. Remove the cylinder head cover.
2. Block the crankshaft and unscrew the bolt securing the camshaft sprocket (the engine is shown in the removed position).
3. To block the crankshaft, turn on the 5th or 4th gear and ask the assistant to depress the brake pedal.
4. Remove the chain tensioner.
5. Remove the V-belt, see Section Removing and installing/tensioning the V-belt.
6. Raise the car.
7. Block the crankshaft and unscrew the crankshaft pulley bolt.
8. Remove all oil pan bolts that are screwed into the drive chain cover.
9. Unscrew the chain cover.
10. Turn the crankshaft so that the keyway points upwards. Simultaneously polished (shiny) the chain links must match the marks on the camshaft and crankshaft sprockets. If the marks do not match, remove the sprocket from the camshaft and adjust the chain.
11. If the chain is adjusted correctly, install the camshaft sprocket, timing chain housing, cylinder head cover, crankshaft belt pulley and oil pan bolts.