Auto Manual of VW Passat B5

2.4.2. A head of the block of cylinders

THE GENERAL DATA

Head of the block of cylinders of the engine 1,8-I

1 – a cover маслозаливной mouths, 2 – a nut of fastening of a cover of a head of the block of cylinders, 10 Nanometers, 3 – a cover of a head of the block of cylinders, 4 – a lining. At lining installation put on its surfaces a thin layer of hermetic D2. 5 – дефлектор oils, 6 – a head of the block of cylinders, 7 – a lining of an inlet collector. At installation it is necessary to use only a new lining.

8 – a lining of a head of the block of cylinders. At installation it is necessary to use only a new lining. After installation of a head of the block of cylinders it is necessary to fill in a fresh cooling liquid. 9 – a bolt for fastening of a tension roller, 25 Nanometers, 10 – a lining of a final collector. At installation it is necessary to use a new lining. 11 – bolts of fastening of a head of the block of cylinders. At installation it is necessary to use only new bolts. 12 – a thermofilter, 13 – the screw, 25 Nanometers, 14 – the screw, 10 Nanometers.

In this subsection operations on removal of a head of the block of cylinders on the four-cylinder petrol engine 1,6-I and 1,8-I are stated.

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The prevention

Before removal of a head of the block of cylinders check up that all hoses, pipelines and electric sockets are disconnected from a head of the block of cylinders.

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Removal of a head of the block of cylinders make on the cold engine. Removal of a head of the block of cylinders is made together with a final collector. Thus the inlet collector is necessary for removing from a head of the block of cylinders preliminary.

The burnt through or defective lining of a head of the block of cylinders is defined to following signs:

 – Reduction of capacity of the engine;
 – Reduction of level of a cooling liquid. Thus the exhaust pipe leaves white steam;
 – Reduction of level of engine oil;
 – Presence in engine oil of a cooling liquid. Thus oil level increases. At presence in engine oil of a cooling liquid engine oil gets grey colour and has foam vials;
 – Engine oil presence in a cooling liquid;
 – Intensive allocation of bubbles from a cooling liquid;
 – Compression reduction in two next cylinders of the engine.

Removal

Arrangement of bolts of fastening of an inlet collector on the engine of 125 h.p.

Sequence of unscrewing of bolts of fastening of a head of the block of cylinders

PERFORMANCE ORDER

1. Check up that the engine cold. Otherwise give time for engine cooling. 2. Switch off ignition and remove a wire of weight from the accumulator. 3. Merge from system of cooling of the engine cooling liquid. 4. Mark high-voltage wires in figures and remove high-voltage wires from spark plugs. 5. Clear candles, using a brush, a vacuum cleaner or a stream of compressed air that will exclude dirt hit in cylinders of the engine after вывинчивания spark plugs. Unscrew spark plugs, using a candle key. 6. Remove pressure in fuel system. For pressure removal in fuel system wrap up a junction of fuel hoses and, being careful, slowly ослабьте connection, thus gradually pressure in fuel system will decrease. 7. Mark and disconnect submitting and returnable fuel hoses from the fuel distributor. Before отсоедине нием hoses ослабьте a collar also move it on a hose. 8. After a detachment close the ends of pipelines suitable stoppers. 9. Disconnect electric sockets from fuel atomizers and move a fuel highway downwards. Mark and disconnect from a head of the block of cylinders all electric sockets. 10. Unscrew from a head of the block of cylinders an arm supporting an inlet collector about a regulator of pressure of fuel. 11. Unscrew an inlet collector from a head of the block of cylinders, the Arrangement of bolts of fastening of an inlet collector fig. see the engine of 125 h.p.). 12. Unscrew an inlet collector from two резинометаллических support and move aside from a head of the block of cylinders. 13. Mark and disconnect from a head of the block of cylinders hoses of system of cooling. 14. Unscrew a reception exhaust pipe with the catalyst from a final collector. 15. Remove the top casing of a gear belt. For a bolt of fastening of a pulley of a cranked shaft turn a cranked shaft of the engine clockwise before combination of adjusting labels on pulleys from the index ми. Thus the piston of the first cylinder will be in ВМТ in a compression step. 16. Using a paint or a marker, note position of a pulley of a cranked shaft in relation to the block of cylinders and turn a cranked shaft of the engine on 90 clockwise that any piston was not in the top dead point. Before installation of a gear belt establish a cranked shaft in position in which the piston of the first cylinder is in ВМТ in a compression step. 17. In the sequence shown on fig. Sequence of unscrewing of bolts of fastening of a head of the block of cylinders, gradually and in regular intervals unscrew bolts of fastening of a head of the block of cylinders. 18. Check up that all pipelines, hoses and electric sockets are disconnected from a head of the block of cylinders. 19. Remove a head of the block of cylinders from the engine and establish it on two wooden бруска. 20. Remove a lining of a head of the block of cylinders.

Preparation of a head for installation

Place of measurement of height of a head of the block of cylinders

And = 139,2 mm for engines of 1,8 l And = 132,6 mm for engines of 1,6 l

PERFORMANCE ORDER

1. Remove plastic заглушки, intended for protection of open valves of a head of the block of cylinders. 2. Interfaced surfaces of a head and the block of cylinders should be absolutely pure. For their clearing use a firm plastic or wooden scraper. The prevention At clearing be careful, as the aluminium alloy is very easy for damaging. 3. Check up, that the deposit has not got to oil and water channels. It is especially important for greasing system as the deposit can block oil giving to engine components. If necessary clear channels. 4. Check up interfaced surfaces of a head and the block of cylinders on presence of notches, deep scratches and other damages. If defects small, they can be removed machining. The prevention The height of a head of the block of cylinders after machining should make for the engine of 1,8 l = 139,2 mm, and for the engine of 1,6 l = 132,6 mm. 5. Using a metal ruler and щуп, check up planeness of interfaced surfaces. The deviation from planeness should be no more than 0,1 mm. 6. Clear apertures under bolts in the block of cylinders. Bolt screwing up in the aperture filled with oil can break off the block because of hydraulic pressure. The prevention At installation of a head of the block of cylinders it is necessary to use new bolts of fastening of a head of the block of cylinders and a new lining of a head of the block of cylinders.

Installation

Places ввинчивания directing pins VW-3070 or VW-3450 in the block of cylinders of the engine


Sequence of a tightening of bolts of fastening of a head of the block of cylinders on four-cylinder engines


Places of drawing of hermetic D2 before installation of a lining of a cover of a head of the block of cylinders

PERFORMANCE ORDER

1. For correct installation of a head of the block of cylinders and a lining of a head of the block of cylinders screw in in an extreme aperture of the block of the cylinders, the fastenings of a head of the block of the cylinders intended for bolts, directing pins VW-3070 (for engine AHL VW-3450). In the absence of directing pins they can be made independently for what it is necessary to use two old bolts of fastening of a head of the block of cylinders. Cut off from bolts of a head and instead of them cut a groove for a screw-driver. After installation of a head of the block of cylinders, using a screw-driver, unscrew directing pins, Place fig. ввинчивания directing pins VW-3070 or VW-3450 in the block of cylinders of the engine see. The prevention At installation of a head of the block of cylinders it is necessary to use a new lining. Take a lining from tight packing directly ahead of installation on the block of cylinders. 2. Check up that the new lining of a head of the block of cylinders has the same type, as the original, and that marks of TORAHS or OBEN are directed upwards. Arrange a new lining of a head of the block of cylinders on a surface of the block of cylinders on directing pins. Check up that apertures were correctly combined with channels of system of cooling and greasing. 3. Being careful, establish a head on the block of cylinders. 4. Insert and tighten manually 8 bolts with washers of fastening of a head of the block of cylinders. 5. A screw-driver unscrew two directing pins and on their place screw in two bolts of fastening of a head of the block of cylinders. 6. Gradually in the sequence shown on fig. Sequence of a tightening of bolts of fastening of a head of the block of cylinders on four-cylinder engines, tighten in some stages bolts of fastening of a head of the block of cylinders. The prevention Do not tighten bolts of fastening of a head of the block of cylinders on the heated-up engine. At installation of a new head of the block of cylinders with a camshaft after installation of a head of the block of cylinders grease with a thin layer of greasing interfaced surfaces of hydraulic pushers and camshaft cams. 7. Turn cranked and distribute тельный shaft in such position that they corresponded to installation of the piston of the first cylinder in ВМТ in a compression step. 8. Before installation of an internal lining of a cover of a head of the block of cylinders grease the surfaces interfaced to a lining, a thin layer of hermetic D2 (fig. of the Place of drawing of hermetic D2 before installation of a lining of a cover of a head of the block of cylinders see). Establish a lining of a cover of a head of the block of cylinders. 9. Establish a cover of a head of the block of cylinders both gradually and consistently crosswise tighten nuts of fastening of a cover. 10. Establish a gear belt on a pulley of a camshaft and adjust its tension. 11. Screw a reception exhaust pipe. 12. Establish an inlet collector with a new lining on a head of the block of cylinders and fix its bolts, having tightened their demanded moment. 13. Screw the bottom part of an inlet collector to резинометаллическим to support. 14. Establish an arm between a head of the block of cylinders and an inlet collector. 15. Connect submitting and returnable топливопроводы to a fuel highway. 16. According to earlier made marks connect to a head of the block of cylinders all electric sockets. 17. Establish casings of a gear belt. 18. Check up that all hoses, pipelines and electric sockets are connected according to earlier made marks. 19. Check up level of engine oil and, if necessary, finish it to norm. If in an old lining of a head of the block of cylinders there were defects, replace engine oil. 20. Fill in cooling liquid in cooling system. 21. Fill in cooling liquid in cooling system. 22. Connect a weight wire to the accumulator. 23. Start the engine and warm up it to working temperature. Switch off the engine and check up level of engine oil and cooling liquid, and also tightness of all connections.