5.7. Head of the block of cylinders

Forward section of an inlet collector
Switch off ignition and disconnect a wire of "weight" from the rechargeable battery.

Fig. 3.3-24. Arrangement of screws of fastening of a casing of the engine



Turn out screws and remove an engine casing (see fig. 3.3-24).
Disconnect a vacuum hose of management of a folding shutter at its existence.
Disconnect an air inlet hose from a folding shutter and move hoses aside.


Fig. 3.3-51. Head of the block of cylinders: 1 – head of the block of cylinders; 2 – laying of a cover of a head of the block of cylinders; 3 – bolts of fastening of a head of the block of cylinders; 4 – cover of a head of the block of cylinders; 5 – maslootrazhatelny ring; 6 – laying; 7 – cover; 8 – fuel tubes of nozzles; 9 – fuel return tubes; 10 – sealing ring; 11 – hollow bolt, 5 N · m; 12 – inlet collector; 13 – bolt, 10 N · m; 14 – laying; 15 – the aligning plug; 16 – nut, 10 N · m; 17 – thermofilter of the vacuum pump; 18 – bolt; 19 – vacuum pump, 10 N · m; 20 – sealing rings; 21 – laying of a head of the block of cylinders



Fig. 3.3-52. Arrangement of bolts of fastening of forward section of an inlet collector



Unscrew bolts and remove forward section of an inlet collector (fig. 3.3-52).
Installation is carried out to the sequences, the return to removal.

Left section of an inlet collector
Remove forward section of an inlet collector.

Fig. 3.3-4. An arrangement of bolts of fastening of the thermofilter over a turbocompressor



Unscrew bolts and remove the thermofilter over a turbocompressor (see fig. 3.3-4).
Mark and disconnect fuel tubes from nozzles.
Release and move a plait of wires from the left section of an inlet collector aside.

Fig. 3.3-53. Arrangement of bolts of fastening of the left section of an inlet collector



Unscrew bolts and remove the left section of an inlet collector (fig. 3.3-53).
Installation is carried out to the sequences, the return to removal.

Right section of an inlet collector
Remove forward section of an inlet collector.
Disconnect vacuum hoses from a turbocompressor and mechanical valves of system of recirculation of the fulfilled gases and move hoses aside.
Mark and disconnect fuel tubes from nozzles.
Release fuel-supply lines and take them aside from the right section of an inlet collector.

Fig. 3.3-54. Arrangement of bolts of fastening of the right section of an inlet collector



Turn out bolts and remove the right section of an inlet collector (fig. 3.3-54).
Installation is carried out to the sequences, the return to removal.

Left cover of a head of the block of cylinders
Remove forward section of an inlet collector.
Release and move a plait of wires from the left cover of a head of the block of cylinders aside.
Mark and disconnect fuel tubes from nozzles.

Fig. 3.3-55. Arrangement of nuts of fastening of the left cover of a head of the block of cylinders and tube (1) of return of fuel



Unscrew hollow bolts and remove tubes of return of fuel 1 (fig. 3.3-55) from nozzles.
Unscrew nuts and remove the left cover of a head of the block of cylinders.
Installation is carried out to the sequences, the return to removal, taking into account the following.
Replace sealing rings of tubes of return of fuel.
Replace the damaged laying of a cover of a head of the block of cylinders.
If sealing rings of fuel nozzles are damaged, it is necessary to replace a cover of a head of the block of cylinders.
Degrease the surface interfaced to laying of a cover of a head of the block of cylinders.

Fig. 3.3-56. Places of putting sealant before installation of a cover of a head of the block of cylinders



Apply a thin continuous layer of sealant on a semicircular surface (fig. 3.3-56) in an end face of a head of the block of cylinders.
Apply with sites of projections 5 mm a layer of sealant with a diameter of 3 mm on external covers of the camshaft (see fig. 3.3-56).
Tighten nuts of fastening of a cover of a head of the block of cylinders gradually and cross-wise.
Connect fuel tubes.
Establish forward section of an inlet collector.

Right cover of a head of the block of cylinders
Prevention
All clips and collars which at removal of a cover of a head of the block of cylinders will be damaged or cut need to be replaced with covers of a head of the block of cylinders, new at installation.

Unscrew screws and remove an engine casing (see fig. 3.3-24).
Weaken collars and remove an air branch pipe from the air filter.

Fig. 3.3-57. Fastening of pipes to a turbocompressor



Weaken and remove pipes from a turbocompressor (fig. 3.3-57).
Mark and disconnect fuel tubes from nozzles.
Release and move a plait of wires from the right cover of a head of the block of cylinders aside.
Unscrew bolts and remove the pipe connecting a turbocompressor to an air cooler.
Unscrew a bolt of fastening of a pipe for the probe of level of engine oil.
Unscrew hollow bolts and remove fuel return tubes.
Unscrew nuts and uncover a head of the block of cylinders.
Installation is carried out to the sequences, the return to removal, taking into account the following.
Replace sealing rings of tubes of return of fuel.
Replace the damaged laying of a cover of a head of the block of cylinders.
If sealing rings of fuel nozzles are damaged, it is necessary to replace a cover of a head of the block of cylinders.
Degrease the surface interfaced to laying of a cover of a head of the block of cylinders.
Apply a thin continuous layer of sealant on a semicircular surface (see fig. 48) in an end face of a head of the block of cylinders.
Apply with sites of projections 5 mm a layer of sealant with a diameter of 3 mm on external covers of the camshaft (see fig. 3.3-56).
Tighten nuts of fastening of a cover of a head of the block of cylinders gradually and cross-wise.
Connect fuel tubes.

Left head of the block of cylinders
Prevention
All clips and collars which at removal of a cover of a head of the block of cylinders will be damaged or cut need to be replaced with heads of the block of cylinders, new at installation.

Before a detachment of the rechargeable battery find out whether you have a code of turning on of the radio receiver.
Switch off ignition and disconnect a wire of "weight" from the rechargeable battery.
Merge cooling liquid from the cooling system.
Take off a gear belt from camshaft pulleys.
Remove forward section of an inlet collector.

Fig. 3.3-58. Arrangement of screws of fastening left (1), top (2) and right (3) casings of a gear belt



Unscrew screws and remove the top section of a casing of a gear belt 2 (fig. 3.3-58).
Unscrew screws and remove left 1 and right the 3rd casings of a gear belt.
Weaken collars, unscrew three bolts and remove cooling system hoses from the forward party of the engine.
Disconnect electric wires from incandescence candles.
Turn out a bolt of fastening of the valve of system of recirculation of the fulfilled gases to the left section of an inlet collector.
Release and move a plait of wires from the left head of the block of cylinders aside.

Fig. 3.3-11. An arrangement of collars of fastening of hoses of the cooling system to heater unions on a partition of a motor compartment



Weaken collars (see fig. 3.3-11) and disconnect the cooling system hoses going to a heater.
Weaken collars and disconnect hoses from a cooling system pipe, and also unscrew a bolt of fastening of a pipe.
Mark and disconnect fuel tubes from nozzles.
Unscrew hollow bolts and remove from fuel 1 return tube nozzles (see fig. 3.3-55).
Unscrew nuts and uncover a head of the block of cylinders.

Fig. 3.3-59. Sequence of tightening of bolts of fastening of a head of the block of cylinders



In the sequence, the return to tightening, gradually weaken, and then unscrew completely bolts of fastening of a head of the block of cylinders (fig. 3.3-59).
Remove a head of the block of cylinders and establish it on the soft basis.

Right head of the block of cylinders
Prevention
All clips and collars which at removal of a head of the block of cylinders will be damaged or cut need to be replaced with heads of the block of cylinders, new at installation.
Before a detachment of the rechargeable battery find out whether you have a code of turning on of the radio receiver.
Switch off ignition and disconnect a wire of "weight" from the rechargeable battery.
Merge cooling liquid from the cooling system.
Remove the right final collector together with a reception exhaust pipe.
Take off a gear belt from camshaft pulleys.
Remove forward section of an inlet collector.
Weaken and remove pipes from a turbocompressor (see fig. 3.3-57).
Unscrew bolts and you peremetit a cover of the air filter aside, without disconnecting from it hoses.
Remove the case of the air filter.
Unscrew bolts and remove the thermofilter over a turbocompressor (see fig. 3.3-4).

Fig. 3.3-12. An arrangement of the electric socket of the sensor (1) in a hose (2) air supply to an inlet collector



Disconnect the electric socket from the sensor of 1 air branch pipe (see fig. 3.3-12).
Remove a hose of air supply 2 to an inlet collector.

Fig. 3.3-60. Fastening of a tube of supply of oil to a turbocompressor  and an inlet collector


Disconnect a tube of supply of oil from a turbocompressor (fig. 3.3-60).
Disconnect a tube of supply of oil from an inlet collector (see fig. 3.3-60).

Fig. 3.3-61. Arrangement of bolts (1) of fastening of a pipe (2) of the cooling system and direction of its movement



Fig. 3.3-62. Marking of laying of a cover of a head of the block of cylinders openings (1), number (2) and code of production (3)



Unscrew two bolts of fastening of a pipe of the cooling system, move it to a back part of the engine and leave in this situation (fig. 3.3-61).
Unscrew a bolt of fastening of the right pipe of the cooling system to an intermediate ledge, without separating a pipe.
Unscrew bolts of fastening of the right pipe of the cooling system to a head of the block of cylinders.
Unscrew bolts and remove the top casing of a gear belt.
Remove the right inlet collector.

Fig. 3.3-2. An arrangement of a clamp of a casing and the direction of turn at removal of the fan of a radiator with the electric drive



For removal of the fan of a radiator with the electric drive disconnect the electric socket from the fan, take a casing clamp, then turn a casing counterclockwise (see fig. 3.3-2) and remove the fan.
Unscrew bolts of fastening of the generator, but do not disconnect from it a wire.
Unscrew a bolt of fastening of a pipe for the index (probe) of level of engine oil.
Unscrew hollow bolts and remove fuel 1 return tubes (see fig. 3.3-55) from nozzles.
In the sequence, the return to tightening, gradually weaken, and then unscrew completely bolts of fastening of a head of the block of cylinders (see fig. 3.3-59).
Remove a head of the block of cylinders and establish it on the soft basis.

Preparation of a head for installation
Privalochny surfaces of a head and the block of cylinders have to be absolutely pure. For their cleaning use a firm plastic or wooden scraper. When cleaning be careful as it is very easy to damage aluminum alloy. Make sure that the deposit did not get to oil and water canals. It is especially important for the lubrication system as the deposit can block supply of oil to engine details. If necessary clean channels.
Check privalochny surfaces of a head and the block of cylinders for existence of notches, deep scratches and other damages. Small defects can be removed with machining. At major defects of a detail are subject to replacement.
Check planeness of a privalochny surface of a head of the block of cylinders.
Clean openings under bolts in the block. Screwing up of a bolt in the opening filled with oil can break off the block because of the increased hydraulic pressure.

Installation of a head of the block of cylinders
Installation is carried out to the sequences, the return to removal, taking into account the following.
At installation of a head of the block of cylinders it is necessary to replace with new samokontryashchiyesya of a nut and bolts which tightened a dovorachivaniye on a certain corner, and also sealing rings and laying.
New laying of a head of the block of cylinders needs to be taken from packing just before installation.
If new pistons are installed on the engine, it is necessary to measure a vystupaniye of pistons from the block of cylinders and according to this value to choose thickness of new laying of a head of the block of cylinders (fig. 3.3-59).
Vystupaniye        Chislo
pistons, mm        of openings
                 0,39-0,49 1
                0,49-0,54 2
                0,54-0,65 3

Establish laying on the directing pins, at the same time the inscription "oben" has to be directed to a head.
If works on the valvate mechanism were carried out, turn manually the engine on two whole revolutions to be sure that pistons did not hit against valves.

Fig. 3.3-37. An arrangement of the adjusting screw 3242 for fixing of a bent shaft



Before installation of a head of the block of cylinders install the piston of the first cylinder and the camshaft in VMT in a compression step. Record a bent shaft in this situation, having unscrewed the sensor of the moment of injection of fuel from the block of cylinders and instead of it having screwed in the adjusting screw 3242 (see fig. 3.3-37).
Insert bolts of fastening of a head of the block of cylinders and tighten them by hand, and then in the sequence shown in the figure 3.3-59 in four stages:
1st –35 N · m;
2nd –60 N · m;
– to tighten the 3rd on a corner 90 °;
– to tighten the 4th on a corner 90 °.
Further additional pulling up of bolts of fastening of a head of the block of cylinders is not required.
Establish a cover of a head of the block of cylinders.
At installation of the directing pipe for the index (probe) of level of engine oil it is necessary to establish a new sealing ring.
Establish a gear belt.
Establish a final collector.
Establish poliklinovy a belt.
Fill in fresh cooling liquid.
Remove air from a power supply system with fuel.
Connect a wire of "weight" to the rechargeable battery.
Turn on the radio receiver and enter into it a code.
Lift glasses power windows up to an emphasis. Then press all switches of a window regulator once again, at least for 1 second, in the provision of closing for activation of the control unit of window regulators.
Determine time on hours.