Contents: Removal ↳ Installation ↳
Four-cylinder petrol engine.
To remove the cylinder head, the engine must be cooled to room temperature. The intake and exhaust manifolds do not need to be removed. The cylinder head seal is defective by one or more of the following signs:
- Loss of power.
- Loss of coolant. White thick exhaust gases when the engine is hot.
- Loss of oil.
- Coolant in engine oil, oil level does not decrease, but increases. Gray color of engine oil, foam bubbles on the oil level indicator, oil is too thin.
- Engine oil in coolant.
- The coolant is spurting out violently.
- There is no compression in two adjacent cylinders.
Removal
Disconnect the negative (-) cable from the battery.
Warning! This will erase data in electronic memory devices, such as the engine fault memory device or the radio code. Please read the section carefully "Removing and installing the battery", before disconnecting it.
Drain the coolant, see p. 3.3.
Remove the air filter and air intake pipe, see p. 5.6.
Squeeze the plastic tabs on the fuel supply lines "1" and remove the fuel lines. Wrap the end of the line with a rag so that fuel cannot splash out of the fuel line when it is removed. Close the ends of the fuel lines with suitable plugs; for these purposes, you can use, for example, clean screws of a suitable diameter. To simplify installation, mark the fuel lines with adhesive tape before removing.
Caution: Remove the fuel lines carefully to slowly release the pressure in the fuel system.
Remove clip "2" and disconnect the gas rod.
Disconnect plug "1" of the power steering push switch. Unscrew the pressure pipe bracket "2" from the engine.
Unscrew the ground wire from the engine lifting eye.
Remove the vacuum hoses from the fuel pressure regulator "2" and from the suction pipe. The figure also shows: 1 - return fuel line; 3 - distribution tube; 4 - valve; 5 - plug for jets; 6 - fuel supply line.
Disconnect the multi-pin plug near the throttle body pipe.
Remove the vacuum hoses from the exhaust gas recirculation valve branch pipe "4", "3" at the measurement point "2" of the pipe "1". Remove the engine ventilation hose near the ignition coil.
From the bottom of the vehicle, remove the vacuum hose from the control valve "5" of the pulse air system.
Remove the wire plug from the ignition coil and from the EST sensor near the ignition coil, see p. 4.3.
Unscrew the front exhaust pipe from the exhaust manifold.
Remove the wheel arch trim "1", unscrew the V-belt pulley cover "2".
Remove the V-belt, see paragraph 1.19.
Remove the brake booster vacuum hose from the intake manifold. To do this, press the retaining clip on the intake manifold slightly into the manifold, hold it in this position and carefully pull the hose out of the spring sleeve.
Unscrew the heat shield from the intake manifold.
Unscrew the bracket-holder of the engine wire bundle from the intake manifold, two bolts.
Remove the hose clamps, remove the coolant hoses from the thermostat, see p. 3.5.
Disconnect the coolant temperature sensor connectors from the thermostat housing and the crankshaft position sensor on the flywheel.
Unscrew the air pulse system filter "8" secured with one bolt from the engine block. 11 - exhaust manifold.
Support the engine with a jack under the oil pan. Use wooden shims to prevent damage. The engine should be slightly raised on the jack.
Unscrew the fastening nuts on the right engine shaft support. Remove the bracket.
Attention! The engine must be supported by a reliable support, otherwise it will fall down.
Remove the front retaining plate from the cylinder head. To do this, unscrew the two bolts "1" on the cylinder head and the two bolts on the power steering pump bracket.
Remove the timing belt, remove the camshafts, see p.1.3.
Caution! It is not necessary to remove the crankshaft sprocket and the lower crankshaft protective cover, since it is not necessary to remove the timing belt.
Using a long Torx socket wrench (size T55), unscrew the cylinder head bolts, starting with bolt 10, in reverse order.
Caution! Loosening the cylinder head bolts may cause deformation or large cracks in the cylinder head.
Check that all hoses and wires running from the cylinder head to the engine and body have already been removed.
Pull out the oil level indicator.
Then, with the help of an assistant, remove the cylinder head from the engine.
Caution! After removing the cylinder head, do not place it on the sealing surface, otherwise you may damage the fully open valves. The cylinder head can only be placed on two wooden blocks.
Installation
Before installation, use a suitable scraper to clean the sealing surfaces of the cylinder block and cylinder head from seal residue. Do not scratch the surfaces. Do not allow seal residue to enter the openings. Cover the openings with rags.
Check the cylinder head for cracks, check the working surfaces of the cylinders for grooves.
Check if the cylinder head bolt holes are clean, if there is oil in them, blow the holes with compressed air. If there is no compressed air, take a thin screwdriver, wrap it in a rag that absorbs well, and clean the bolt holes.
Attention! The oil from the holes must be removed in any case.
To center the cylinder head, you need to make guide pins. To do this, take two old cylinder head bolts, cut off the heads and cut slots in them for a screwdriver.
Screw the guide pins into the bolt holes 7 and 8 (see Fig. F-10144).
Make sure the guide bushings are seated correctly in the engine block. The guide bushings must fit securely in the bolt holes "4" and "6".
Position the cylinder head gasket so that the "TOP/OBEN" marking faces the cylinder head. Cylinder head gaskets have teeth on the leading edge. The new gasket should have the same markings as the old one.
Attention! To avoid damage to pistons and valves, it is necessary to turn the crankshaft before installing the cylinder head so that the piston of the first cylinder is at a distance of 20 mm from TDC. After completing the installation of the cylinder head and camshafts, i.e. when they are at TDC, turn the crankshaft so that it is again at TDC for the first cylinder.
Carefully install the cylinder head without damaging the seal.
Use a screwdriver to unscrew the guide pins.
Lightly oil the head and threads of the new cylinder head bolts and screw them in by hand.
Caution: Use only new cylinder head bolts.
Tighten the cylinder head bolts in three stages in order 1-10. Stage 1: Tighten with a torque wrench to 30 Nm. Stage 2: Tighten with a torque wrench to 50 Nm. Stage 3: Tighten the bolts further with an open-end wrench by 90° (1/4 turn).
Attention! Once the bolts have been tightened, they must not be tightened any further. The bolts must be tightened very carefully and the accuracy of the torque wrench must be checked before tightening. In addition, an angle washer, such as HAZET 6690, is required to tighten the cylinder head bolts. If such a washer is not available, place the wrench on the bolt, measure 90° with a protractor and mark this angle with chalk on the cylinder head.
Install the camshafts, see p. 1.4.
Install the timing belt, see p. 1.3.
Bolt the front bracket and the power steering pump bracket to the cylinder head. Tighten the three bolts to 50 Nm.
Screw the right engine bracket with new self-locking nuts. Lower the jack, tighten the nuts to a torque of 90 Nm.
Remove the jack.
Attach the engine wire guide to the intake pipe with two bolts.
Snap the brake booster vacuum hose into the quick-release fastener on the intake manifold
Screw the heat shield to the exhaust manifold. At the same time, screw the coolant pipe and oil level indicator bracket.
Screw on the front exhaust pipe, see item 8.
Install all electrical wires and vacuum hoses in accordance with the marks made during dismantling and secure them.
Install the gas rod.
Connect the supply and return fuel lines in accordance with the markings and secure the quick-lock fasteners.
Connect the ventilation hose to the cylinder head.
Install the V-belt, see paragraph 1.19.
Install the belt pulley cover.
Install the air filter and air intake pipe, see p. 5.6.
Check the engine oil level, top up if necessary. If the cylinder head was removed due to a defective seal, then the engine oil should be changed completely, including the oil in the filter, since the engine oil contains coolant.
Check if the coolant contains antifreeze and add it, see p. 3.3.
Connect the ground wire to the battery (-). Set the clock, set the anti-theft code for the radio.
Warm up the engine to operating temperature, check all fluid levels and check all hose connections for leaks.
(For more information, please visit the website: FORDBOOK)