Diesel engine cylinder head
- 1 - the upper part of the casing of the toothed belt;
- 2 - toothed belt. Check the condition of the toothed belt. Before removing the toothed belt, it is necessary to put an arrow on it indicating the direction of rotation of the toothed belt. Do not bend the toothed belt;
- 3 - nut, 20 Nm;
- 4 - bolt, 20 Nm;
- 5 - bolt, 45 Nm;
- 6 - toothed belt pulley. Removing the camshaft timing belt pulley from the camshaft mounting cone is done using a punch passed through a hole in the rear timing belt casing;
- 7 - tension roller;
- 8 - guide roller;
- 9 - rear casing of the toothed belt;
- 10 - bolt, 10 Nm;
- 11 - eye;
- 12 - a bolt of fastening of a head of the block of cylinders. At installation it is necessary to use new bolts;
- 13 - oil shield;
- 14 - cylinder head cover. The cylinder head cover seal is vulcanized to the cover, so if the seal is damaged, the cylinder head cover must be replaced;
- 15 - sealing cuff. If damaged, a new seal must be used;
- 16 - cover;
- 17 - ventilation pipe to the air intake;
- 18 - clamp;
- 19 - pressure reducing valve. For crankcase ventilation system;
- 20 - seal. If damaged, a new seal must be used;
- 21 - bolt, 5 Nm;
- 22 - high pressure fuel lines, 25 Nm. High pressure fuel lines must be replaced as a set. It is not allowed to bend pipelines;
- 23 - vacuum pump. For vacuum brake booster;
- 24 - seal. When installing, a new seal must be used;
- 25 - fuel injector;
- 26 - glow plug, 15 Nm;
- 27 - cylinder head gasket. When installing, use a new gasket and fill the cooling system with fresh coolant
Diesel engine head cover gasket marking
- 1 - spare part number;
- 2 - code;
- 3 - gasket characteristic
The cylinder head must be removed when the engine is cold. The cylinder head is removed together with the intake and exhaust manifolds.
A burnt or defective cylinder head gasket is determined by the following signs:
- reduction in engine power;
- decrease in coolant level. At the same time, white steam comes out of the exhaust pipe;
- decrease in engine oil level;
- the presence of coolant in the engine oil, while the oil level increases. If there is coolant in the engine oil, the engine oil turns gray and has foam bubbles;
- the presence of engine oil in the coolant;
- intensive release of bubbles from the coolant;
- reduction of compression in two adjacent engine cylinders.
Removing
1. Check that the engine is cold. Otherwise, allow time for the engine to cool down.
2. Switch off ignition and remove a wire of weight from the accumulator.
SDI engine
3. Remove the intake manifold.
TDI engine
4. Remove the pipe connecting the charge air cooler and the intake manifold.
5. Drain the coolant from the cooling system.
6. Disconnect the cooling system hoses from the front and left side of the cylinder head and move them to the side.
7. Disconnect the electrical connector from the 0.3 bar oil pressure sensor.
8. Unscrew the voltage supply rail from the glow plugs. Unscrew the glow plugs. Clean the piping connections to the fuel injectors and high pressure fuel pump. Unscrew the connecting nuts and remove the fuel lines. Close the holes with suitable plugs.
9. Unscrew from a head of the block of cylinders fuel atomizers.
10. Loosen or cut the clamp and remove the crankcase ventilation hose from the intake manifold. Release the retaining clip and remove the crankcase ventilation hose from the cylinder block. Remove the sealing ring.
11. Raise the vehicle.
12. Unscrew the front exhaust pipe from the exhaust manifold or turbocharger. Using a soft wire, hang the exhaust pipe to the body.
13. Remove the top casing of a gear belt.
14. Loosen the toothed belt tension and remove it from the camshaft pulley.
15. Loosen the camshaft pulley bolt half a turn. Remove the camshaft timing belt pulley from the camshaft alignment cone using a drift through the holes in the rear timing belt housing. Unscrew the bolt and remove the camshaft pulley.
16. Unscrew bolts of fastening of a back casing of a gear belt.
17. In the sequence shown in the figure, unscrew the cylinder head bolts half a turn, and then unscrew the bolts in the same sequence.
18. Check that all pipes, hoses and electrical connectors are disconnected from the cylinder head.
19. Remove the cylinder head from the engine and place it on two pieces of wood. When removing the head, press the rear casing of the toothed belt.
Warning: Do not rotate the camshaft with the cylinder head removed. If the camshaft is set to the position of the piston of the first cylinder at top dead center on the compression stroke, then the cams of the camshaft of the first cylinder must be directed upwards. In this position, the locking tool can be inserted into the groove in the end of the camshaft.
20. Remove the cylinder head gasket.
Installation
1. The mating surfaces of the head and cylinder block must be perfectly clean. Use a hard plastic or wooden scraper to clean them. Be careful when cleaning as aluminum alloy is very easy to damage.
2. Check that carbon deposits do not get into the oil and water channels. This is especially important for the lubrication system, as deposits can block the oil supply to engine components. Clean channels if necessary.
3. Clean the bolt holes in the cylinder block. Screwing a bolt into an oil-filled hole can rupture the block due to hydraulic pressure.
4. Using a metal ruler and feeler gauge, check the flatness of the mating surfaces.
5. The deviation from flatness should be no more than 0.1 mm.
6. If new pistons are installed on the engine, it is necessary to measure the protrusion of the pistons from the cylinder block and, based on the protrusion of the pistons, select the thickness of the new cylinder head gasket (see fig. Diesel engine head cover gasket marking).
7. When installing the cylinder head, a new gasket must be used. Remove the gasket from its sealed package just before installing it on the cylinder block.
8. To properly install the cylinder head and the cylinder head gasket, screw the VW 3070 guide pins into the extreme holes of the cylinder block intended for the cylinder head bolts. If there are no guide pins, you can make them yourself, for which you need to use two old cylinder head bolts cylinders. Cut off the head bolts and cut a slot for a screwdriver instead. After installing the cylinder head, use a screwdriver to unscrew the guide pins.
9. Using paint, mark the installation position of the crankshaft pulley. Then turn the engine crankshaft 1/4 turn to ensure that none of the pistons is at top dead center. Before installing the toothed belt, it is necessary to set the crankshaft in a position in which the piston of the first cylinder will be at TDC on the compression stroke.
10. Being careful, establish a head of the block of cylinders.
11. For fastening of a head of the block of cylinders use only new bolts. Screw in bolts of fastening of a head of the block of cylinders by hand.
12. Unscrew the two guide pins with a screwdriver and screw in the two cylinder head bolts in their place.
13. Gradually, in the sequence shown in the figure, tighten the cylinder head bolts in several stages. Stage 1 - 40 Nm. Stage 2 - 60 Nm. Stage 3 - turn 90°. Stage 4 - turn 90°.
14. Further tightening of the cylinder head is not required.
15. Turn the engine crankshaft 1/4 turn so that the number one piston is at TDC on the compression stroke. Check that the camshaft is set to the position corresponding to the installation of the piston of the first cylinder at TDC on the compression stroke. Lubricate the working surfaces of the tappet and camshaft cams with clean engine oil.
16. Screw in bolts of fastening of a back casing of a gear belt.
17. Install the toothed belt.
Warning: Be sure to remove the injection pump pulley fixing tool.
18. Install the cylinder head cover and tighten the cover nuts to 10 Nm.
19. Establish the top casing of a gear belt.
20. Connect the exhaust pipe to the exhaust manifold or turbocharger.
21. Lower the car.
SDI engine
22. Install the intake pipe.
TDI engine
23. Install the pipe between the charge air cooler and intake pipe and secure it with clamps.
24. Connect the hoses to the cylinder head.
25. Fill the engine cooling system with fresh coolant.
26. Screw in the glow plugs.
27. Screw in the fuel injectors.
28. Connect ground wire to battery.
29. Check the engine oil level and top up if necessary.
30. Start the engine and warm it up to normal operating temperature.
31. Check the condition and tightness of the cooling system.
32. Check the injection timing of the high pressure fuel pump.
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