Attention: This chapter contains special features that are unique to this engine series. For general information on minor engine repairs, refer to previous chapters.
Withdrawal
Disconnect the ground wire.
Attention: In this case, information about malfunctions is erased from the on-board computer battery.
Raise the vehicle.
Remove the front silencer pipe from the exhaust manifold.
Remove the front muffler pipe from the turbocharger.
Drain the coolant from the engine.
Turn away bolts of fastening of an inlet collector and remove fastening.
Remove the following hoses from the mountings on the cylinder head: brake booster vacuum hose (1), heater water hose (2), fuel hose to high pressure fuel pump (3).
Disconnect the vacuum hose from the inlet (at the EGR valve).
Disconnect the intake manifold temperature sensor connector by depressing the wire bracket.
Open the intake manifold.
Loosen the union nuts on the injection pipes on the injectors and on the high pressure fuel pump. Close the holes with plugs.
Disconnect the cables from the glow plugs.
Remove the V-belt. Loosen the cylinder head cover bolts first ½ turn and then completely.
Unscrew the hydraulic V-belt tensioner and disconnect the damper.
Attention: Store the removed tensioner only in an upright position. Otherwise, there may be violations in its work.
Turn away two bolts and remove the vacuum pump. Bolt (2) at the same time it serves to fasten the guide chain.
Set the piston of the first cylinder to the top dead center position. To do this, engage the fifth gear and turn the crankshaft pulley in the direction of engine rotation until the camshaft cams of the intake and exhaust valves of the first cylinder (from the drive chain) will face each other. The arrows on the sprockets of both camshafts must point upwards.
Lock the crankshaft at top dead center. To do this, insert the rod through the hole in the engine block into the hole in the flywheel.
Fix the camshaft with a tool. Unscrewing the camshaft sprocket can be dispensed with without a tool by holding the camshaft by a 27 mm hexagon.
Insert a suitable clamping lever at the chain tensioner bar and press the tensioner.
Unscrew the plug and fix the tensioner in a compressed state.
Unscrew the tensioner retaining pin from the cylinder head and remove the O-ring.
Loosen the chain guide retaining pin and remove the O-ring.
Loosen the gear box cover bolts. Fastening (1) made in the form of a stud and a nut.
Remove the bolt (arrow), and disconnect the drain hose from the nozzle.
In sequence 14 to 1, first loosen the cylinder head bolts 1/2 turn and then back out completely.
Remove the cylinder head.
Installation
Check the position of the centering sleeves (arrows).
Apply a new gasket without sealant so that it does not block the holes. The new gasket should be the same thickness as the removed gasket.
If it is not clear which gasket to install, it is necessary to measure the piston protrusions. The thickness of the gasket is selected according to the maximum protrusion of one of the 6 pistons. To measure, place a dial indicator at point A and, with a slight crankshaft rotation in both directions, determine the highest position. Then repeat the measurement at point B. The average value between the measurements at points A and B gives the value «piston protrusion». Take these measurements on all six pistons.
Attention: However, if one or more cylinders have a piston protrusion greater than 0.81mm, a three-hole gasket is installed.
Install the cylinder head. In this case, the mark on the high pressure pump must be facing upwards.
Insert and hand tighten the cylinder head bolts lubricated with engine oil.
The cylinder head bolts are tightened in 6 steps. On each pass, tightening is performed in sequence from 1 to 14.
- 1st reception - tightening with a torque wrench with a force of 80 Nm.
- 2nd technique - tightening with a wrench 180°and then releasing the bolts.
- 3rd reception - tightening with a torque wrench with a force of 50 Nm.
- 4th reception - tightening with a 90°wrench.
- 5th reception - tightening with a 90°wrench. After 25 minutes of engine operation (after installing it).
- 6th reception - tightening with a 90°wrench.
Replace the seal on the high pressure fuel pump support. Apply sealant at the junction with the gear box cover.
Install the gear box cover, tighten the bolts to 10 Nm.
Tighten the fasteners next to the injector, and also put the fuel return hose on the injector.
Screw in the two retaining pins for the tensioner and chain guide with new O-rings.
Screw the sprocket with the chain overlay to the camshaft, do not tighten the bolt yet.
Remove the blocking rod from the chain tensioner so that the chain is tensioned. Screw the plug into the hole in the cylinder head. For high mileage circuits on the intake valve side of the head cylinders should install a gasket (probe) thickness A = 4.61 mm. If the template is not used, rotate the camshaft about 2°to the left and in this position hold it by the 27 mm hex.
In this position, tighten the camshaft sprocket in two steps.
- 1st reception - with a torque wrench with a tightening force of 20 Nm.
- 2nd reception - tightening with a hard wrench at 35°.
Insert the vacuum pump together with the O-ring, the driver should engage with the cutout in the camshaft sprocket.
Insert shock absorber and V-belt tensioner bracket and secure.
Install the V-belt. Attach the front muffler pipe with a new gasket with new self-locking nuts to the turbocharger. Coat the bolts with high temperature paste first.
Connect the wires to the glow plugs. Push the connectors in until you hear a click.
Insert injection tubes. Tighten the union nuts with a special wrench to a tightening torque of 20 Nm.
Replace intake manifold gaskets. After that, install the intake manifold, tighten the bolts crosswise with a torque of 25 Nm.
Install the intake manifold mounting bolts.
The diesel engine is equipped with a wider ribbed V-belt driving the alternator, water pump and power steering pump.