Removal and installation of a head of the block of the diesel engine 1.8

Disconnect the ground wire from the battery clamp.

Drain the coolant into a prepared container. If the coolant has been in operation for no more than two years and is free from contamination, it can be used in the future.

Remove the upper coolant hose. connecting the radiator to the thermostat housing.

Disconnect the tube from the intake manifold through which air is drawn in.

Remove the air intake muffler together with the air filter.

Remove the suction muffler housing.

Disconnect the vehicle heating hoses.

Disconnect the vacuum pipe connecting the vacuum pump to the brake booster mechanism, as well as the oil drain pipe from the engine lubrication system.

Remove the fuel return overflow pipes from the injectors.

Remove the high pressure fuel lines as a set (pic. 2.65). Close their openings immediately using plastic caps.



Remove the oil dipstick bracket.

Remove the thermostat housing.

Disconnect the flexible hoses from the injection pump connecting it to the fuel supply pump.

Remove the fuel filter.

Remove the front exhaust pipe mounting bolts from the exhaust manifold. Hang the exhaust pipe after disconnection.


Remove the alternator mounting and remove the V-belt.

Remove the top casing of a gear belt.

Unscrew the bolts securing the generator casing. and remove the TDC dowel pin socket cap. Turn the crank like this. so that the elongated hole of the gear driving the injection pump is in the position corresponding to 11 o'clock on the hour dial.

Screw the TDC setting pin into the appropriate socket in the engine housing.

Slowly rotate the crankshaft until it is in the correct position relative to the TDC locating pin.

Slightly loosen the center bolt of the gear mounted on the camshaft.

Remove the camshaft timing belt tensioner.

Remove the camshaft timing belt.

Remove the gear mounted on the camshaft.

Remove the timing gear (pic. 2.66).



Remove both parts of the back cover.

Remove the side bottom cover.

Unscrew the nozzles using the GV-2304 wrench.

Remove the sprayer covers.

Remove the spark plug electrical wire harness.

Unscrew the spark plugs.

Remove the block head cover.

Unscrew the fixing bolts and remove the block head. These bolts cannot be reused. When installing the head of the block, you must use new bolts.


If there is oil and water in the cylinders, remove them.

The block head is installed in the reverse order. In addition, when installing the block head, you must follow the steps below:

Degrease the seating surface of the block head.

Select the block head gasket according to the instructions contained in the subsection on engine installation.

Before installing the block head, it is necessary to install the camshaft in the position shown in fig. 2.67.



Only new bolts must be used to fasten the block head. The bolts must be tightened in the order shown in fig. 2.68.



Bolt tightening torques and angles are given in section 1.1. During the installation of the head of the block, it is necessary to strictly maintain the required values of the moments and angles of tightening.

The toothed belt drive must be assembled according to the instructions in section 2.3 "Engine assembly".

The cooling system must be bled after filling with liquid. The pumping method is given in section 2.8 "Cooling system".