Fig.4.25. Elements of fastening of a head of cylinders: 1- oil supply pipe; 2 - oil return pipe; 3 - gasket for oil return pipe; 4 - sealing ring; 5 - cylinder head bolt, 30 Nm + 100±4°+ loosen + 25 Nm + 213±7°; 6 - cylinder head; 7 - cylinder head gasket
Removing
- Disconnect the wire from the negative battery terminal.
- Remove the lower engine mudguard.
- Reduce the pressure in the fuel system.
- Drain the coolant from the cooling system.
- Remove the plug and drain the engine oil from the engine.
- Remove the air filter and air intake pipe.
- Remove the catalytic converter.
- Remove the exhaust pipe and main muffler.
- Remove the timing belt drive timing.
- Disconnect the connectors from the camshaft position sensor, fuel pressure sensor, high pressure fuel pump, fuel temperature sensor, fuel injectors, glow plugs, coolant temperature sensor, and EGR solenoid valve (pic. 4.22).
Pic. 4.22. cylinder head: 1 - camshaft position sensor connector; 2 - fuel pressure sensor connector; 3 - high pressure fuel pump connector; 4 - fuel temperature sensor connector; 5 - fuel injector connector; 6 - glow plug connector; 7 - coolant temperature sensor connector; 8 - connector for the exhaust gas recirculation solenoid valve; 9 - vacuum hose; 10 - vacuum hose of the vacuum brake booster; 11 - upper radiator hose; 12 - hose of the engine cooling system; 13 - heater hoses; 14 - fuel return hose; 15 - fuel supply hose
- Loosen the clamp and disconnect the brake booster vacuum hose.
- Disconnect vacuum hoses.
- Loosen the clamp and disconnect the upper radiator hose from the cooling system pipe.
- Loosen the clamp and disconnect the engine cooling system hose.
- Loosen the clamps and disconnect the heater hoses.
- Disconnect the fuel supply and return hoses. To prevent dirt and foreign matter from entering the fuel system, plug all open fuel system connections with plugs.
- Remove the bolt securing the oil supply pipe. Loosen the union nuts and remove the oil supply pipe.
- Remove the two bolts and remove the oil return pipe and gasket
- Remove the O-rings from the bottom of the oil return tube.
- In the sequence shown in Figure 4.23, loosen and remove the cylinder head bolts in 2 or 3 passes.
Pic. 4.23. The sequence of turning out the bolts of the cylinder head
Warning. At installation it is necessary to use new bolts of fastening of a head of cylinders.
- Being careful, remove a head of the block of cylinders.
- Remove the cylinder head gasket.
- Cover the engine cylinders with a clean, lint-free cloth.
Installation
- Installation is carried out in the reverse order of removal, taking into account the following.
- Degrease the mating surfaces of the block and cylinder head.
- At installation check up coincidence of all openings on a lining and a head of cylinders.
- Install the gasket and cylinder head to the cylinder block.
- In several stages, in the sequence shown in Figure 4.24. tighten the cylinder head bolts
Pic. 4.24. Cylinder head bolt tightening sequence
Steps for tightening the cylinder head bolts:
1. In the sequence shown in Figure 4.24, tighten the new bolts to 30 Nm.
2. In the same sequence, tighten the bolts at an angle of 100±4°, for which you install a special tool on the wrench that ensures the bolts turn at a strictly defined angle.
3. Wait 3 minutes for the cylinder head gasket to shrink.
4. Loosen bolts #1 and #2
5. Tighten bolts No. 1 and 2 to 25 Nm.
6. Tighten bolts No. 1 and 2 at an angle of 213±7°, for which, install a special tool on the wrench that ensures the bolts turn at a strictly defined angle.
7. Divide the remaining bolts into pairs: bolts #3 and 4, bolts #5 and 6, bolts #7 and 8, bolts #9 and 10. Tighten the bolt pairs as recommended in steps 3, 4, and 5.
Warning. When tightening the cylinder head bolts, they stretch. If the cylinder head bolt is too tight, replace it with a new one, do not retighten.
- Install the oil supply pipe and tighten the union nuts. Screw in the bolt of the oil supply pipe.
- Install the oil return pipe and gasket.
- Remove the plugs and connect the fuel supply and return hoses.
- Connect heater hoses and secure with clamps.
- Connect the engine cooling hose.
- Connect the upper radiator hose to the cooling system inlet.
- Connect vacuum hoses.
- Connect the vacuum hose of the vacuum brake booster.
- Connect all previously disconnected electrical connectors.
- Connect the exhaust pipe and main muffler.
- Install the catalytic converter.
- Install the air filter and air intake pipe.
- Install the timing belt drive of the gas distribution mechanism.
- Install the lower engine mudguard.
- Fill the engine with the required amount of the recommended engine oil.
- Pour coolant into the cooling system.
- Connect the wire to the negative battery terminal.
- Start the engine and check for leaks.