If the installed charge air hoses are not degreased and damp, the turbocharger may fail.
1. Disconnect the negative cable from the battery.
2. Remove the lower protective casing of the engine compartment
3. Loosen the screws and remove the EC cover).
4. Disconnect the connector.
5. Disconnect all electronics connectors (1 and 2) engine management systems.
6. Disconnect connectors (1 and 2) glow plug relay.
7. Remove the relay (1) with base and fuses (2). Disconnect connector (3), remove the protective cap (4), give the nut and disconnect the positive wire (5) battery.
8. Give the nut (1), press the latch (2) and disconnect the diagnostic connector (3).
9. Remove seal (1) and take out the box (2) electrical wiring upwards.
10. Press the latches (1), remove the box cover (2) wiring harness, pull the wiring harness out of the box and fix it on the engine.
When installing, pay attention to the guides (3).
11. Remove the battery positive cable terminal cap.
12. Give a nut.
13. Release the clamps (1), and release the positive wire (2) from holders (3).
14. Remove the transmission oil line holder from the engine oil pan. Loosen the battery positive wire clamps.
15. Remove AT (see chapter automatic transmission).
16. Remove the radiator of the engine cooling system (see chapter Engine cooling, heating, ventilation and air conditioning systems).
17. Press the brake pedal several times to reduce the vacuum in the brake booster.
18. Press the latch (1) and at the same time disconnect the vacuum hose together with the connection (2).
When installing, check the sealing ring of the connection and replace it if necessary. Disconnect the vacuum hoses (2, 3 and 5) from the vacuum pipeline (6).
vacuum hoses
19. Turn out bolts (1) and move aside the vacuum line (2). Press the latch (1) and disconnect the fuel line (3) from the preheat valve. Open the yoke (2), remove the fuel line (3) and fix it on the engine. Disconnect the connector (4), press the lock (5), disconnect the fuel supply line (6) and fix it on the engine.
Fuel line connections
Collect leaking fuel.
20. Release the clamps (1) and remove the right (2) and left (3) charge air hoses.
When installing, place the clamps in their original places.
Hoses must be dry and free of grease.
21. Loosen clamps (1) and remove the pressure hose (2) assembled. Loosen clamp (3) on the intercooler and remove the pressure hose (4) complete with pressure tube.
Hoses must be dry and free of grease.
22. Loosen clamp (1) on the intercooler and remove the pressure hose (2) complete with pressure pipe. Loosen clamp (3) and remove the pressure hose (4) to the side.
Hoses must be dry and free of grease.
23. Remove the tensioner of the A/C compressor drive belt (see Section Removal and installation of drive belts and their tensioners).
24. Remove the bolt (1) and loosen the clamp (2).
25. Disconnect the connector (1), remove the bolts (2), remove the power steering pump (3) from the upper section of the oil pan and secure the pump with wire to the front axle beam.
26. Remove the bolt (3) and release the wire (4) from the holder.
27. Loosen the clamp (1) and remove the hose (2) charge air together with the charge air piping.
Hoses must be dry and free of grease.
28. Disconnect the suction pipe (1) away from the turbocharger and move a little to the side. Remove the bolts (2) fixing the A/C compressor, lower the compressor down and disconnect the electrical wire from it.
Do not disconnect pipelines of the A/C system.
29. Give the nut (1) and remove the wire (2) masses. Give the pillow nut (3) engine mounts and disconnect the vacuum hose (4) from the adapter.
30. Release the latches (1 and 3) and disconnect the water hoses (2 and 4). Tie the wiring harness (5) AT to the turbocharger on the right side. Secure the positive battery cable behind the flywheel.
31. Slightly lift the motor by the lifting eyes and remove the suction tube (1) in the direction indicated by the arrow.
32. 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.
33. Installation is carried out in the reverse order of the dismantling of the components.
34. After installation, before starting the engine, check the levels of working fluids and, if necessary, correct them.
35. After carrying out work between the fuel tank and the injection pump, the fuel supply system must be bled to avoid running the injection pump in a dry state and damaging it. To bleed air from the injection pump, perform the following operations:
- Disconnect the supply pipeline from the injection pump;
- Turn on the ignition;
- Wait for the fuel to come out without bubbles and turn off the ignition;
- Install the supply pipe with a new clamp.
36. Start the engine and check for fuel and fluid leaks, and for abnormal noises and vibrations.
37. Let the engine idle, then turn it off and check fluid levels again.