Removal and installation of the cylinder head

1. Disconnect the negative (-) cable of the battery when the ignition is off. You must first remove the air filter box of the passenger compartment.

Before disconnecting the cable, find out the radio security code, if any, address to Section Replacement of the battery. Operation lifting and car installation on supports is connected with danger! Therefore, prior to the operation to check out the Poddomkrachivanie and towing Introduction to management.

2. Lift and establish the car on supports.
3. Remove the bottom cover of the engine compartment, refer to the appropriate section.
4. Drain coolant, refer to Section Replacement of a cooling liquid - general comments.
5. Disconnect the generator connector.
6. Disconnect the turbocharger at the bottom of the holder.
7. Disconnect the oil sensor connector.
8. Remove the engine covers, refer to the appropriate section.
9. Remove the air filter, refer to Section Removal and installation of the air filter.
10. Remove the guide tube holder the oil level indicator on the right rear of the cylinder head.
11. Disconnect the glow plugs, coolant temperature, the fuel pressure sensor and the pressure control valve at the cylinder head.
12. Disconnect the ground cable near the valve with electric disconnection at the cylinder head.
13. Disconnect the cable holder near the pressure control valve at the cylinder head.
14. Remove the cover of the thermostat, refer to Section Removal and installation of the thermostat.
15. Remove the nozzle, refer to Section Removal and installation of atomizers.
16. Remove the cylinder head cover, refer to the appropriate section.
17. Remove the chain tensioner, refer to Section Removal and installation of chain tensioner.
18. Establish the piston of the first cylinder to TDC refer to the appropriate section.

Do not rotate the engine backwards. In no case did not turn over the engine bolt camshaft sprocket.

19. Remove the front cover from the cylinder head, refer to the appropriate section.
20. Remove the top guide, refer to the appropriate section.
21. Remove the camshafts, refer to the appropriate section.
22. Remove the cover of camshafts.
23. Remove the pump.
24. Remove the intermediate asterisk, refer to the appropriate section.
25. Remove the charge air distributor.
26. Remove the oil feed line to the turbocharger.
27. Remove the coolant hose to the generator.
28. Remove the pre-catalytic converter from the engine block.
29. Remove the turbocharger from the exhaust manifold.

The exhaust manifold is still attached to the cylinder head.

30. Remove the cylinder head bolts to the housing cover timing.
31. Remove the cylinder head bolts in the reverse numbering, ie 12 to 1
(4-cylinder engine) or 14 to 1 (5-cylinder engine). At the same time, first loosen all bolts ½ a turn and then remove the bolts.
32. With the help of an assistant, lift the cylinder head. On HUNDRED head lifted by a hoist or workshop crane. To do this, grab the ropes for two eyelets on the exhaust manifold.

Before installing the cylinder head and remove the remains of sealant scraper with mating surfaces. Make sure that no remnants of sealant into the holes. Close the holes with rags. After cleaning, remove the cloth.
1. Check the steel ruler flatness of the block and the cylinder head in the longitudinal and transverse directions, if necessary, treat the (work HUNDRED).
2. Check the cylinder head for cracks, and working surfaces of cylinders in the presence of the grooves.
3. Thoroughly clean the holes for the cylinder head bolts from the oil and other products. Blow holes with compressed air or a screwdriver to remove the oil, wrapped in cloth.

Holes for the cylinder head bolts should be free from residues of oil and coolant. Otherwise, when screwing bolts will create new pressure, which can lead to the destruction of the cylinder or incorrect assessment of torque.

4. The cylinder head gasket must be replaced.
5. Place in place a new gasket without sealant so as not to block any aperture.
6. Replace with the help of the assistant to the place of the cylinder head. Make sure that when installing the cylinder head is not skewed.

The cylinder head on the cylinder block is centered guide bushings.

7. Measure the length of the cylinder head bolts. The length of the new bolts is 102 mm. Each tightening bolts are extended. When reaching the length of 104 mm or more bolts must be replaced.

8. Oil the threads and bearing surface of bolts and screw on hand to fit to the head. Tighten the cylinder head bolts should be done with special care. Before tightening the torque wrench should be checked for accuracy. Tightening at a given angle should be done with the use of angular washer, for example, HAZET 6690. In order not to overload the torque wrench high torque, angle, use a washer with a conventional key. If the angular washer is not available, one can estimate the angle anyway. To do this, the hard key so that the key grip is along the engine and turn the key in one step so as to handle the situation across the occupied engine.

9. Tighten the cylinder head bolts in three steps, in sequence to the specifications 1 to 10.

10. Tighten the screws Torx (11) and (12) securing the cylinder head to the housing cover timing torque 20Nm.

11. Tighten the cylinder head bolts in the five techniques in order to specifications.

12. Secure the turbocharger to the exhaust manifold torque 30Nm.
13. Fix the pre-catalytic converter in the engine block.
14. Install the coolant pipe going to the generator.
15. Secure the oil supply pipe with new gaskets on the turbocharger and torque 30Nm torque on the cylinder head 22 nm.
16. Install the charge air distributor.
17. Install the intermediate asterisk, refer to the appropriate section.
18. Install the fuel pump. Attach the high pressure pipe from the pump and pipeline momentum 22nm.
19. Install camshaft housing.
20. Install the camshafts, refer to the appropriate section.
21. Install the top guide, refer to the appropriate section.
22. Install the front cover on the cylinder head, refer to the appropriate section.
23. Install chain tensioner with a new seal, refer to Section Removal and installation of chain tensioner.
24. Install the cylinder head cover, refer to the appropriate section.
25. Install the nozzle, refer to Section Removal and installation of atomizers.
26. Set the thermostat casing, address to Section Removal and installation of the thermostat.
27. Attach the cable holder near the pressure control valve on the cylinder head.
28. Attach the ground cable near the electric control valve off with the cylinder head.
29. Dock glow plugs, coolant temperature sensor, a pressure sensor in the fuel line and pressure control valve on the cylinder head.
30. Fix the holder guide tube oil dipstick gearbox at the rear right cylinder head.
31. Install the air filter, refer to Section Removal and installation of the air filter.
32. Install the engine covers, refer to the appropriate section.
33. Dock connector Sensor oil.
34. Attach the bottom bracket from the turbocharger torque 30Nm.
35. Dock connector generator.
36. Install the lower engine compartment lid, refer to the appropriate section.
37. Lower the car on wheels.
38. Check the engine oil level.
39. Fill the coolant system, refer to Section Replacement of a cooling liquid - general comments.
40. Connect the negative (-) cable to the battery when the ignition is switched off. Replace the cabin air filter box. Enter the code of the radio and set the time on the clock.
41. Check for leaks engine against oil and coolant. At the same time, check the cooling system for leaks when the engine reaches operating temperature.

Cylinder head gasket leak only becomes when the engine warms up to operating temperature, and a lining swells accordingly.