Contents: Removal ⬇ Installation ⬇
Removal
Note: Do not begin work on dismantling the cylinder head until the engine has cooled below 35°C. Otherwise, damage to the cylinder head may occur. Move all pistons away from TDC.
1. Drain all coolant from the cooling system into a previously prepared container.
2. Remove the thermostat housing from the cylinder head.
3. Remove the upper timing chain cover (more details, see the relevant section in this chapter).
4. Remove the lower timing chain cover (more details, see the relevant section in this chapter).
5. Remove the upper attachment mounting bracket.
6. Remove the turbocharger assembly with the exhaust manifold (for more details, see the corresponding section in the chapter Intake and exhaust system).
7. Remove the intake manifold assembly (for more details, see the relevant section in the chapter Intake and exhaust system).
8. Remove the expansion tank of the engine cooling system.
9. Install a special device for hanging the power unit (T30099) assembled with the MP9-200/3 bracket above the engine compartment, as shown in the figure below.
10. Unscrew the gearbox mounting bolt to the engine and screw the T10358 mounting bracket mounting bolt in its place.
11. Using the MP9-200/3 spindle, slightly lift the power unit assembly.
12. Disconnect the fuel lines (3) and (4) shown in the figure below. To do this, press the release buttons.
Caution: Fuel supply line under excess pressure. To prevent injury, wear safety glasses and gloves. Before opening the system, place a clean rag around the connection.
13. Loosen the fastening nut (1). Disconnect the ground wire (housing) (2) from the engine support, as shown in the figure below.
14. Unscrew the mounting bolts (arrows), remove the engine support.
15. Remove the cylinder head cover (more details, see the relevant section in this chapter).
16. Remove the tensioner and guide rails of the camshaft drive chain.
17. Remove the rocker arms together with the hydraulic tappets and place them on a clean surface.
18. Do not disassemble rocker arms and hydraulic compensators.
19. Unscrew the cylinder head mounting bolts in the sequence shown in the figure below.
20. Carefully remove the cylinder head assembly.
Installation
Note: The tightening torque of the check valve (arrow) shown in the figure below is 7 Nm.
Note: Neither piston should be at TDC.
Note.
- The new cylinder head gasket should only be removed from its packaging immediately prior to installation.
- The new gasket must be handled with extreme caution. Damage will cause leaks.
- Do not allow any amount of oil or coolant to be present in the holes for the cylinder head mounting bolts.
1. Seal the cylinders with clean rags to prevent any dirt from getting into the space between the cylinder walls and the pistons.
Caution: When working with the seal remover and degreaser, wear protective gloves and goggles.
2. Make sure that no contaminants enter the cylinders or the lubrication and coolant passages during cleaning of the cylinder head and block.
3. Carefully remove any remaining old gasket from the cylinder head and cylinder block using a chemical gasket remover.
4. Set the piston of the 1st cylinder to TDC, turn the crankshaft back a little.
5. Install a new cylinder head gasket. Inscription (part number) should be directed upwards.
6. Install the cylinder head assembly onto the cylinder block. In doing so, be guided by the centering pins in the cylinder block.
7. Install new cylinder head mounting bolts and tighten by hand.
8. The cylinder head mounting bolts should be tightened in the sequence shown in the figure below as follows:
- All bolts must be tightened to a torque of 40 Nm.
- Then turn all bolts an additional 90° (¼ turn) using a socket wrench.
- Then turn all bolts another 90° (¼ turn).
9. Install the hydraulic compensators in the cylinder head and place the corresponding rocker arms on the ends of the valve stems.
10. Install the cylinder head cover (more details, see the relevant section in this chapter).
11. Adjust the valve timing (more details, see the relevant section in this chapter).
12. Further installation is carried out in the reverse order of removal.
13. Fill the cooling system with coolant, then remove air from the system.