Removal and installation of the cylinder head

1. Remove the air filter (2), depending on the model of the engine, together with the executive body for the circulation valve.
2. Remove the engine cover (7/11).
3. Remove the cylinder head cover, refer to the appropriate section.
4. Remove the air intake.
5. AT models: Disconnect vacuum line at an electric vacuum pump. At the same time squeeze the two clips lock and pull out the pipe. Remove the outlet pipe from the vacuum pipe.
6. Remove the clamp pipe EGR holder. Remove the diverter valve to the holder. This disconnect from the valve the two vacuum lines. Then disconnect the holder from the inlet pipeline.
7. Models with AT: Remove the guide pipe the oil level indicator gearbox around eyes.
8. Remove the fuel distribution manifold with injectors.
9. Remove the bolts and remove the intake pipe from the cylinder head. Disconnect vacuum hose recirculation valve. Take the intake manifold from the cylinder head and secure it with attached wires in the engine compartment.
10. Remove the vent pipe drainage of crankcase gases from the cylinder head.

11. Disconnect ventilation hoses engine (1) under the flange of the intake pipe and the cylinder head.

12. Remove the V-belt drive compressor, refer to the appropriate section.
13. Remove the suction and delivery connections of the compressor.
14. Remove the compressor.
15. Lift and establish the car on supports. Remove facing the engine compartment at the bottom.
16. Drain the cooling liquid, address to Section Replacement of a cooling liquid - general comments.
17. Disconnect the receiving pipe exhaust system from the exhaust manifold. Remove the tube from the holder of a transmission. Slightly lower the exhaust system and secure it with wire or cable connector.
18. Remove the EGR pipe from the cylinder block. Remove the recirculation pipe holders the right and left rear of the cylinder head.
19. Remove the coolant hose heater. To do this, press the bracket so that it engages. After that, remove the coolant pipe.
20. Set the piston of the first cylinder in position of 20 ?� after TDC. To do this, rotate the crankshaft pulley in the direction of rotation of the motor so that the mark of 20 ?� on the pulley coincides with the mark on the cover of the housing allocation mechanism. In this position, the cams of the first cylinder intake camshaft and the exhaust camshaft have to stand up at an angle.
21. Remove the thermostat housing, refer to Section Removal and installation of the thermostat.

22. Remove the front cover (3). To do this, remove the 2 mounting bolts (1) on both sides of the front cover (3). Bolts are thread diameter of 8 mm, in addition the back cover has guides. Remove the bolts (2) (the thread diameter of 6 mm) and remove the cover (3). Note the presence of the counter-ring between the cover and the cylinder head. Clean the mating surfaces.

23. Mark the paint gear camshaft with respect to the circuit.
24. Remove the chain tensioner, refer to the appropriate section.

25. Remove the upper guide bearings. To do this, pull the thread of the finger guide (1) with a shock device for drawing (2) or any other suitable tool. To ensure this sliding cargo device relative to the abutment.

26. Remove the gear of the exhaust camshaft. When unscrewing the bolts holding the camshaft from turning the hexagon.
27. Remove the bolts from the bearing cap of the inlet camshaft. Bolts loosen in stages. Put the screws so that they can be set in place.
28. Remove the sprocket chain drive of the inlet camshaft.
29. Remove the inlet camshaft.
30. Remove the finger of the left rail.
31. Remove the bolts and remove the timing housing from the cylinder head.
32. Loosen the bolts of the cylinder head cover of the engine is cold in the reverse order of their consolidation, and then remove the bolts.

33. Measure the length of M12 bolts fastening the cylinder head. The length of the new bolts is L = 102 mm. After each tightening bolt length increases. With a length of 106 mm or more bolts must be replaced. It is recommended to use only new bolts.

34. With the help of an assistant, remove the cylinder head.

Installation is performed in reverse order of removal. It is necessary to observe the following:

1. Clean the contact plane of the cylinder head and cylinder block and check for cracks and irregularities. Clean the threaded holes.
2. Install the new gasket.

3. Place the cylinder head so that the guide sleeve in the cylinder block into the holes in the cylinder head. When installing the cylinder head follow the guides. Tighten the cylinder head bolts should be done with great care. Before tightening, check the accuracy of the torque wrench. To facilitate the bolts at a predetermined angle can be applied angular washer, for example, HAZET 6690. In order not to load the torque wrench is a great moment, the angular washer should be used together with the hard key. If the angular washer is not available, make an assessment of the angle of rotation of the key. To do this, the hard key so that the key grip stood along the engine and turn the key at a time so that the handle has become perpendicular to the engine. Specifications of the cylinder head shown in the specification.

4. Oil the threads and bearing surface of the head cylinder head bolts and tighten in the specified sequence from 1 to 10, first to fit to the cylinder head, and then quoted in the specification highlights:

5. Lightly oil the bearing surfaces of the heads of new bolts (A) of the cylinder head to timing housing cover and screw bolts. Tighten bolts to the specified torque.
6. Apply sealant ?�Omnifit FD 3041" before you install the finger guide. Fix the top moment of 10Nm.
7. Install the intake camshaft. Lubricate the compensating elements and the bearing seat. Place the shaft so that the cams of the first cylinder standing up at an angle.

When long-term operation of the engine, check the axial play of the camshaft bearing in the installation. Check clearance of camshafts, adjust if necessary.

8. Install the intake camshaft into place and tighten the bolts evenly (risk of damage to the shaft). Camshaft bearings are numbered from 1 to 10, starting from the inlet camshaft. Secure the cover of bearings in stages in increments of one turn, finally tighten to 21Nm.
9. Tighten the gear of the exhaust camshaft with new bolts to 20Nm. Then, tighten the bolts on the angle of 60 ?�.
10. Lubricate the mating surface of the front cover (3) on the cylinder head sealing, for example, ?�Omnifit FD 3041".
11. Insert the rear cover guides for the two screws (1) (the thread diameter 8 mm). Install new O-ring for the coolant and replace the cover.
12. Tighten the screws (1) on both sides of torque 25 Nm, the bolts (2) (the thread diameter of 6 mm) torque 10Nm.
13. Check for damage before installing coolant hose heater, if necessary, replace the hoses. Replace O-ring on coolant supply.
14. Secure the tube EGR to the new O-rings on the cylinder block.
15. Attach the receiving exhaust pipe on the exhaust manifold with new bolts to 20Nm.

Replace rivet nuts in the collector. To do this, an auxiliary screw bolt by hand rivet nut and bolt on the head knock riveting nut. Pull a new rivet nuts and bolts under the caulking and tighten to 30Nm.

16. Fix the holder receiving the pipe on the gearbox torque 20Nm.

17. Secure the inlet pipe (2) with new gasket (1) on the cylinder head torque 20Nm. Pre-clean the mating surfaces.

18. Replace the air intake, check the O-ring. If necessary, replace the ring.