31.1 Timing parts
1 Exhaust valve, no machining allowed, lapping only
2 Cylinder head
3 Valve guide
4 Oil cap
5 Valve spring
6 Spring plate 5
7 Keys for split valve lock
8 Rocker arm with hydraulic valve clearance compensator
9 Exhaust camshaft
10 Cylinder head cover
11 Bolt, to be replaced, 8 Nm, then retighten 90°
12 O-ring, to be replaced, lubricate with engine oil
13 Cork
14 Intake camshaft
15 Cover, to be replaced, pressed without sealant to a depth of 1-2 mm
16 Inlet valve, no machining allowed, lapping only
Removal and installation of camshafts and cylinder head cover
Remark: Machining the upper surface of the cylinder head and the lower surface of its cover is not allowed, because. The camshaft bearings are integrated into the cylinder head and into its cover.
2. Remove the sound insulation under the engine compartment, as well as the locker of the right front wheel arch (see chapter 11).
3. On models with an additional heater, loosen the clamp (1 in illustration 15.14), remove the bolt (2) and remove the auxiliary heater muffler.
4. Turn out bolts (arrows in illustration 25.4), lift the latches (1 and 2) and remove the pressure air tube.
5. Remove the top timing chain cover (see Section 27).
6. Follow the steps in paragraphs 28-33 of Section 30.
7. Remove the air cleaner (see chapter 4).
8. Disconnect the vacuum line (3 on resist. illustrations) at the connecting point (1), disconnect the connector (2) CMP sensor "G40" and unscrew the coolant line fasteners from the vacuum pump (6). Remove injection pump (7, withm. Chapter 4), Vacuum pump (5, see Section 30), ignition coils (4, see chapter 5) and PCV oil separator (8).
31.8 Parts on the cylinder head cover
9. Turn out bolts of fastening of a cover of a head of cylinders in sequence (1-6 per resist. illustrations) and remove the cover. Remove camshafts. Take measures to prevent dirt and sealant residues from entering the cylinder head.
31.9 Sequence of releasing the bolts of the cylinder head cover
10. Remove the remnants of sealing materials from the mating surfaces of the cylinder head and its cover, and then clean them of oil and grease. The use of a chemical sealant and grease remover is recommended.
11. Make sure piston #1 is at TDC and the rocker arms are properly seated at the ends of the valves.
12. Lubricate the bearing surfaces of the camshafts and lay them in the cylinder head so that the samples are vertically opposite each other and facing each other (see resist. illustration).
31.12 Installation position of camshafts
13. Apply a bead of silicone sealant G1 54 1 03A1 with a diameter of 2-3 mm to the cylinder head cover, as indicated on the resist. illustrations. After applying the sealant, the cover must be installed within no more than 5 minutes. The layer of sealant should not be too thick, otherwise the excess sealant will be squeezed inward and may come to clog the oil passages.
31.13 Sealant application scheme
14. Establish a cover of a head of cylinders and in regular intervals tighten new bolts of its fastening in sequence (6-1 in Illustration 31.9) in several approaches: first by hand, then with a force of 8 Nm, and then pull them to an angle of 90°.
15. Using the T10174 mandrel, install a new cover (1 per resist. illustrations) without sealant to the depth (A) ~1-2 mm.
31.15 Installing the cover on the end face of the cylinder head
16. Follow the steps described in paragraphs 44-47 Section 30.
17. Further installation is carried out in the reverse order.
Replacing valve stem seals without removing the cylinder head
18. Remove camshafts (see subsection above).
19. Remove spark plugs (see Section 14 Chapter 1).
20. Remove the rocker arms and lay them on a clean surface so that they can then be installed in their original places.
21. Install the guide plate VAS5161/19B on the cylinder head using the bolts VAS5161/12 as indicated on the resist. illustrations.
31.21 Mounting the guide plate
22. Set the piston of the corresponding cylinder to the bottom dead center position.
23. Screw adapter T40012 into the spark plug hole and apply air at a pressure of at least 6 bar, and then, if the crackers of the split valve lock are jammed, hit the mandrel VAS5161 / 3 on them with a plastic hammer (see resist. illustration).
31.23 Air supply
24. On the intake side, screw the VAS5161 /19 plates into the central threaded hole into the VAS5161 /6 toothed part with the VAS5161/5 fork (see resist. illustration). Then insert the VAS5161/8 cartridge into the VAS5161/19B plate and attach the VAS5161/2 pressure fork to the VAS5161/6 part.
31.24 Inlet accessories
25. On the exhaust side, screw into the external threaded hole of the VAS5161/19B plate the toothed part VAS5161/6 with the fork VAS5161/5 (see resist. illustration). Press the VAS5161/8 cartridge down and at the same time turn its knurled screw to the right until the ends are locked in the breadcrumbs. Slightly move the knurled screw back and forth to wring out the crackers and grab them into the cartridge. Release the pressure fork VAS5161/2 and remove the cartridge VAS5161/8. Remove plate VAS5161/19B.
31.25 Outlet side fittings
26. Pull out the oil seals using the MP1-230 puller (see resist. illustration).
31.26 Removing the oil seal
27. If it is not possible to use the MP1-230 puller due to limited space, knock out the pin (arrow on resist illustrations) and remove the drummer.
31.27 Modification of the MP1-230 puller
28. Place the lower part of the MP1-230 puller on the oil seal cap, insert a drift into its hole (1 per resist. illustrations) and pull the cap in the direction of the arrow.
31.28 Removing the oil seal with a modified puller
29. In order not to damage the new oil seal (B on resist. illustrations), put a plastic sleeve on it (A). Lubricate the sealing lip of the cap, install it in tool MP1-233 and carefully slide it over the valve stem. Remove the plastic sleeve (A), insert the valve spring and its plate.
31.29 Fitting the oil seal
30. On the intake side, bring VAS5161 to the position shown in illustration 31.24.
31. On the exhaust side, bring VAS5161 to the position shown in illustration 31.25.
32. If crackers were removed from the installation cartridge, insert them into the VAS5161/18 tool (see resist. illustration), and then push the VAS5161 /8 cartridge into it from above and grab the biscuits.
31.32 Setting tool VAS5161/18
33. Push the VAS5161/8 cartridge down with the VAS5161/2 pressure fork and turn the knurled screw of the cartridge back and forth while pulling it up. Release the pressure generated by the fork while still pulling the screw up.
34. Remove tool VAS5161.
35. Further installation is carried out in the reverse order.