Attention! Since 05.2005, a modified front (right in the direction of the car) engine mount that no longer needs to be removed when replacing the timing belt.
The illustrations below can help you determine which engine mount is installed in your vehicle.
Attention! After assembly, reinstall all cable ties removed or cut when dismantling the cylinder head.
Removing
1. Remove the engine cover by pulling it up first with a jerk (arrows A), and then forward (arrow B), by detaching it from the rear mount.
2. Remove the plenum box cover.
3. Remove the air filter housing with air flow meter and connecting tube.
4. Loosen the screw (arrow A) and remove the air filter housing from the mounting upwards.
5. Remove the acoustic cover.
6. Drain coolant.
7. Before removing the cylinder head, use a manual vacuum pump to pump out the fuel from the double pump.
8. Disconnect pressure hoses (2) and reverse (1) lines, as well as the hose of the cooling system (3).
9. Remove the fuel filter module from the mount and, without disconnecting the hoses, set it aside.
10. To remove a reception pipe of the muffler.
11. Remove the turbocharger support and oil return line from the turbocharger (for engines 1.9 l).
12. Remove pressure line for oil supply to turbocharger and lay it aside.
13. Remove the timing belt.
14. Remove the toothed belt tensioner.
15. Remove the camshaft sprocket hub.
16. Unscrew the screws securing the rear casing of the toothed belt (2) And (4).
17. Unscrew the sensor (3) camshaft position (G40).
18. Remove the connecting tube of the exhaust gas recirculation system.
19. Disconnect from the cylinder head all other wires that must be disconnected and put them aside.
20. Disconnect all connecting pipes, cooling system hoses, vacuum hoses and air ducts from the cylinder head.
Attention! Both lifting eyes are located on the cylinder head, so an additional bracket must be attached to the engine block to hang the engine on the cylinder block.
21. Suspend the engine so that the weight of the power unit is not applied to the cylinder head.
22. Loosen the cylinder head mounting screws in the sequence shown in the figure, then unscrew the screws and remove the cylinder head.
On vehicles manufactured from 06.2005, the tensioner pulley remains in the engine mount.
Installation
Attention!
- Always install new cylinder head screws.
- When repairing, carefully remove the remnants of the gasket from the cylinder head and from the cylinder block. At the same time, do not leave scratches on the mating surfaces.
- Carefully remove the remnants of abrasive and polishing compounds.
- Remove a new cylinder head gasket from the packaging immediately before installation.
- The gasket must be handled very carefully. Damage to the silicone layer or metal edging of the edges of the gasket can lead to burning it or to the ingress of oil or coolant into the cylinders (into the crankcase) engine.
1. Before installing the cylinder head, turn the crankshaft to the position corresponding to the TDC of the first cylinder.
2. Having turned the crankshaft in the direction opposite to the worker, set it in such a position that the pistons are in the middle position.
3. Install the cylinder head gasket.
Attention!
- The gasket is selected depending on the protrusion of the pistons from the BC (for a description of the gasket thickness selection process, see: «Cylinder head gasket marking» page 142). If the KShM and ShPG have not been repaired, a cylinder head gasket with the same marking as on the old gasket should be used.
- On vehicles produced from 06.2005, the cylinder head must be installed in such a way that the tensioning roller pin fits into the tensioning roller lying in the engine support. This requires the assistance of a second mechanic.
4. Install the cylinder head and manually install all the screws of its fastening.
5. Tighten the cylinder head screws in 4 stages in the following sequence.
- Tighten with a torque wrench;
- stage I: 35 Nm;
- stage II: 60 Nm.
- Tighten the screws with an ordinary wrench:
- step III: tighten 1/4 turn (90°);
- stage IV: tighten 1/4 turn (90°).
Attention! Perform additional tightening of cylinder head screws (after the run, as is done in some cars) not required.
Further installation is carried out in the reverse order. In doing so, attention should be paid to the following.
6. After installing the cylinder head, turn the camshaft pulley so that the pair of cams of the first cylinder are equally directed upwards.
7. Before installing the toothed belt, turning the crankshaft in the working direction, set it to the TDC position of the first cylinder.
8. Install the camshaft sprocket hub.
9. Install toothed belt.
10. Install poly V-belt.
11. Install pressure oil line.
12. Install soundproof casing.
13. Install the plenum box shield.
14. Fill in coolant.
15. Make a test drive, and then interrogate the fault memory of the engine control unit.
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