If the installed charge air hoses are wet and lubricated, the turbocharger may fail.
1. Disconnect the negative cable from the battery.
2. Remove facing of the bottom of a body.
3. Remove the top radiator shroud and cover the generator to prevent contamination.
4. Turn out bolts (1) and remove the air duct (2).
5. Turn out bolts (1) and remove the hose in the direction of the arrow.
At installation grease working edges of sealing rings of a hose with a thin layer of vaseline.
6. Remove corrugated hose (see illustration).
7. Remove cover (1), remove the bolts (2) and remove the case (3) air cleaner.
8. Remove the air cleaner element.
9. Turn out a bolt (1) on the right bracket (2) engine mounts.
10. Loosen clamp (1), remove the pipeline (2) charge air and close the openings on the turbocharger immediately.
11. Loosen clamps (1) and remove the hoses (2 and 3) charge air assembly with charge air line.
12. Turn out bolts (1) on the turbocharger. Remove the pressure transducer bracket and vacuum ignition timing diaphragm mechanism.
13. Remove drive belts (see Section Replacing drive belts and their tensioners).
14. Disconnect connector (1), remove the bolts on the turbocharger (2) and secure it to the side.
15. Remove the coolant hose (1) along with the tank (2).
16. Remove the inlet pipeline (see Section Removal and installation of the inlet pipeline).
17. Remove the radiator of the cooling system (see chapter Engine cooling, heating, ventilation and air conditioning systems).
18. Give the nut (1) on the left engine mount. Release the vacuum hose from the clamp (2) and disconnect the vacuum hose from the adapter below the clamp (2).
19. Turn out bolts (1) and fix the power steering pump (2) aside.
20. Cut the collar (1), disconnect the branch (2) wiring harness.
21. Remove the bolts (1), remove the cover (2) compartment of the ECM.
22. Release the bar clamps (1) and remove it in an upward motion. Disconnect connector (2) from ECM. Remove branch (3) wiring harness.
23. Disconnect the connector (1) from the ECM, disconnect the connectors (2 and 3) and connector (4) glow plug relay. Take out the branch (5) wiring harness from the ECM.
24. Loosen the clamp (1), disconnect the vacuum hose (2), press the latches (3), disconnect the hoses (4) heater and secure them to the side.
25. Fix the vacuum hose, the guide tube of the dipstick of the engine oil level and the positive wire (1) battery with clamp (2) on a vacuum tube (3). Disconnect the fuel supply hose at the fuel filter assembly.
26. Disconnect the clutch (2) valve (3) preheater and set the valve aside.
Clamps (1) should not be weakened.
27. While supporting the hood, lift the clips (1) on both sides and slide up. Disconnect the damper (2) from the hood on the left and right side.
28. Install two M8 bolts (1) in hinges (2) hood, fixing it in this way.
29. Remove cap (1) and give the nut (2). Release the positive wire (3) battery from the holder (4) and attach to the engine.
30. Install tool no. 11 7 050 (1) between the engine oil pan (2) and beam (3) front bridge.
31. Remove the catalytic converter (see chapter Exhaust systems).
32. Remove manual transmission or AT (see chapter Manual gearbox and clutch or automatic transmission).
33. Give the nut (1), disconnect the ground wire (2) and put it aside.
34. Using a special lift, remove the engine up from the engine compartment by the front and rear lugs.
Be careful not to damage components in the engine compartment while lifting the engine.
35. Installation is carried out in the reverse order of the dismantling of the components. Check the integrity of the support pads and replace them if necessary.
36. After installation, before starting the engine, check the levels of working fluids and, if necessary, correct them.
37. Start the engine and check for fuel and fluid leaks, and for abnormal noises and vibrations.
38. Let the engine idle, then turn it off and check fluid levels again.