Removing
Remove the cylinder head on a cold engine in the following order:
- turn off the ignition and disconnect the wire «masses» from the storage battery;
- relieve pressure in the fuel system;
- drain the coolant from the cylinder block and radiator;
- drain the engine oil from the engine and unscrew the oil filter;
- remove the air filter housing;
- remove the distribution fuel line and injectors;
- remove the intake and exhaust manifolds;
- remove the toothed belt, camshaft pulley and toothed belt tensioner;
Pic. 3.35. 3S-FE engine cylinder head: 1 - eye; 2- «mass» the wire; 3 - generator bracket; 4 – laying of a head of the block of cylinders; 5 – a back casing of a gear belt; 6 – a spring of a gear wheel of a camshaft; 7 - spring ring; 8 - wavy washer; 9 - sealing ring; 10 – an auxiliary gear wheel of a camshaft; 11 – a cover of the bearing of a camshaft; 12 - intake camshaft; 13 – a lining of a cover of a head of the block of cylinders; 14 – a cover of a head of the block of cylinders; 15 - intake manifold support; 16 - air pipe; 17 - crankcase ventilation valve (PCV); 18 - spacer sleeve; 19 - intake manifold gasket; 20 - vacuum pipe; 21 - element of the exhaust gas recirculation system; 22 - electro-pneumatic valve of the exhaust gas recirculation system; 23 - gasket; 24 - gasket; 25 - throttle assembly; 26 - intake manifold; 27 - gasket; 28 – fuel vibration damper; 29 - fuel supply pipe; 30 - fuel return pipe; 31 - fuel line; 32 - O-ring; 33 - sealing ring; 34 - nozzle; 35 - washer; 36 - holder of high-voltage wires; 37 - sealing ring; 38 - oil deflector cap; 39 - valve; 40 - spark plug; 41 - adjusting washer; 42 - pusher; 43 - crackers; 44 - spring plate; 45 - spring; 46 - spring plate; 47 - retaining ring; 48 - valve guide sleeve; 49 - exhaust camshaft; 50 - eye; 51 - cylinder head; 52 – O-ring; 53 - gasket; 54 - coolant outlet fitting; 55 - gasket; 56 - oil pressure sensor; 57 - bypass tube of the cooling system; 58 - protection of the oil heat exchanger; 59 - thermal protective casing of the exhaust manifold; 60 - exhaust manifold gasket; 61 - support No. 1 of the exhaust manifold; 62 - support No. 2 of the exhaust manifold; 63 - exhaust manifold
- turn out bolts and remove a back casing of a gear belt 5 (pic. 3.35);
- disconnect the camshaft position sensor;
- remove camshafts 12, 49 and pushers;
- mark and disconnect the remaining pipes of the cooling system, tubes, cables, hoses and wires;
Pic. 3.36. Cylinder head bolt tightening sequence
- hex key «by 8 mm» in the reverse order to tightening, gradually loosen and then completely unscrew the cylinder head bolts (pic. 3.36);
- remove the head from the cylinder block. If the head is too tight, use the lever on the side opposite the toothed belt to separate the head from the cylinder block.
Installation
When installing the block head, you must use new mounting bolts.
Replace all clamps and clamps that are damaged or cut during removal with new ones when installing the head of the block.
When replacing the block head, fill the cooling system with fresh coolant.
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. Make sure that carbon deposits do not get into the channels of the lubrication and cooling system. This is especially important for the lubrication system, as deposits can block the oil supply to engine parts. Clean channels if necessary.
Check the mating surfaces of the head and cylinder block: they should not have notches, deep scratches and other damage. Small defects can be eliminated by machining. In case of significant defects, the parts must be replaced.
Use a tap to clean the threads of the cylinder head bolt holes in the block. Clean the bolt holes in the block. Screwing a bolt into an oil-filled hole can rupture the block due to hydraulic pressure.
Install the parts and assemblies that were removed from the cylinder head.
Check that the guide bushings are installed in the cylinder block.
A new cylinder head gasket must be removed from the packaging immediately before installation.
Install the gasket on the guide bushings, while the inscription «top» should point towards the head.
Install the cylinder head.
Apply a thin layer of engine oil to the threads of the cylinder head bolts, insert the bolts and tighten them by hand.
In the sequence shown in Figure 3.36, in two stages, tighten the cylinder head bolts:
- 1st - tighten with a torque of 49 Nm;
- 2nd - tighten by an angle of 90°.
In the future, additional tightening of the cylinder head bolts is not required.
Further installation of the cylinder head is carried out in the reverse order of removal, taking into account the following.
Check and adjust valve clearances if necessary.
Fill with coolant.
Install a new oil filter and fill the engine with engine oil.
Start the engine and check for leaks.
Adjust ignition timing.
Carry out a road test of the vehicle.