Removal and Installation of Cylinder Head

PROCEDURE

Cylinder Head Bolt Tightening Sequence

Cylinder Head Gasket The red arrow indicates the part number, the blue arrow indicates the notches showing the gasket thickness.

Engine removed from vehicle. PROCEDURE 1. Remove alternator belt and upper camshaft drive cover (see subsection 2.2.3.1).

subsection 2.2.3.1).

2. Remove cylinder head cover. 3. Disconnect the power busbar from the glow plugs and unscrew the glow plugs. 4. Clean the fuel lines at their mounting points on the high-pressure fuel pump and injectors with gasoline, then remove them. Do not bend or alter the shape of the fuel lines. 5. Unscrew the injectors. 6. Remove the intake manifold and exhaust manifold. 7. Set the No. 1 cylinder piston to TDC (see subsection 2.2.3.1). 8. Loosen the camshaft belt tension and remove the belt from the camshaft gear (see subsection 2.2.3.1).

Warning: After the camshaft belt has been removed, do not rotate the crankshaft, camshaft or intermediate shaft. 9. If the engine has covers that fully enclose the camshaft drive, remove fuel pump gear 15 (see illustration Camshaft Drive Components), pump 13, pump bracket 14, camshaft gear and rear cover 21.

10. Using a special tool, loosen the cylinder head bolts. Loosen the bolts evenly in the reverse order of the tightening sequence shown in the figure. Cylinder head bolt tightening sequence. 11. Remove the cylinder head and cylinder head gasket. If the cylinder head is stuck to the block, do not insert screwdrivers or any other tool between the head and the block, as this may damage the head surface. Lightly tap the cylinder head with a hammer through a wooden block. 12. After inspection and replacement of damaged and worn parts, install the cylinder head in reverse order. Replace the cylinder head gasket and cylinder head cover gasket, as well as the cylinder head bolts. Three cylinder head gaskets of different thicknesses are supplied as spare parts. To distinguish the gaskets, they are marked with a part number and have one, two or three notches, as shown in the figure. Cylinder head gasket. The thickness of the gasket to be installed on the engine is determined by the piston protrusion above the cylinder block deck at TDC.

Install a gasket of the same thickness as the old gasket. Starting from September 1995, a gasket with an additional 16 mm diameter hole between cylinders 1 and 2 is installed. 13. If the piston protrusion measurements differ, select the gasket based on the largest piston protrusion value. 14. To facilitate installation of the cylinder head, make guide pins from old cylinder head bolts. Cut off the heads of two bolts and cut a screwdriver slot. Screw these pins into the outer holes on the intake manifold side of the block before installing the head. 15. Tighten the cylinder head bolts in the sequence shown in the figure. Cylinder head bolt tightening sequence, in three stages: – Stage 1 – 40 N·m; – Stage 2 – 60 N·m; – Stage 3 – tighten further by half a turn (180°).

16. After assembly, start and warm up the engine (oil temperature not below 50 °C). Tighten the cylinder head bolts by a further quarter turn (90°). 17. After 1000 km, tighten the cylinder head bolts again by a quarter turn (90°) (except engines model 1V). Engine installed in vehicle. If it is necessary to replace the cylinder head gasket, lap the valves, remove carbon deposits, etc., the cylinder head can be removed without removing the engine from the vehicle. Do not remove the cylinder head from a hot engine (coolant temperature above 40 °C). PROCEDURE 1. Disconnect the negative battery cable. 2. Drain the engine cooling system (see subsection 2.4.1). 3. Disconnect the cooling system hoses from the cylinder head. 4. Remove the air duct from the air filter to the intake manifold or turbocharger. 5. Disconnect the exhaust pipe from the exhaust manifold. 6. Disconnect the electrical wires from the fuel shut-off valve, glow plugs, oil pressure sensor and coolant temperature sensor. 7. Unscrew the glow plugs. 8. Clean and disconnect the fuel lines from the injectors and high-pressure pump. 9. Unscrew the injectors. Further sequence is the same as for an engine removed from the vehicle (see above).