2. Remove the top cooling fan shroud.
3. Empty the engine cooling system (see chapter Vehicle settings and routine maintenance).
If the coolant is not completely drained from the cylinder block, when the cylinder head is removed, it falls into the engine sump.
Left cylinder head
1. Remove left camshafts and intake manifold (see Section Removal and installation of the inlet pipeline).
2. Remove rockers (1) and hydraulic lifters (2) valve clearances. Make sure the rocker rollers run smoothly.
Rocker arms, hydraulic tappets that were in operation should be installed in their original places, so when removing them, lay them accordingly.
3. Release from clips (1) water hose (2) and take him aside.
4. Loosen clamp (1) and disconnect the hose (2).
5. Loosen clamp (1) and disconnect the suction tube (2). Release the pipeline (3) from the holder, disconnect the hose (4), remove the bolt (5) and remove the suction tube (2).
6. Turn out bolts (1) from injection pump (3), divert the pipeline (2) aside and remove the injection pump.
When installing, if necessary, replace the sealing ring under the gear wheel of the injection pump.
7. Turn out both bolts on an air duct and remove it.
When installing, if necessary, replace the O-ring at the end of the duct.
8. Remove hollow bolts (1) and remove the oil pressure pipe (2).
When installing, replace the bolt seals.
9. Turn out a bolt of fastening of directing in a forward part of a head of cylinders.
When installing, use new fasteners.
10. Turn out bolts.
When installing, clean the mating surfaces and replace the flange gasket.
11. Turn out bolts (1), disconnect pressure pipes (2) and remove the fuel rail (3).
12. Disconnect the glow plug connectors. Disconnect the wire (1), lift and secure the hose (2) and tourniquet (3) engine wiring.
13. Loosen clamps (1 and 3) and disconnect the hose (4).
Do not remove the EGR pipe.
14. Turn out three forward bolts on a head of cylinders, and then bolts of fastening of a head of cylinders in reverse sequences.
Cylinder head bolts No. 7-10 and No. 1-6 differ in diameter (M10 and M12). The cylinder head bolts must not be reused. To remove the cylinder head, do not completely unscrew the No. 10 bolt.
15. Remove the cylinder head.
Glow plugs protrude above the bottom plane of the cylinder head, do not damage them, and also do not scratch the mating surfaces of the head.
16. Remove the glow plugs if necessary.
17. Remove the cylinder head gasket and clean the mating surfaces and all blind threaded holes on the crankcase of engine oil and coolant.
Pay attention to the number of holes in the cylinder head gasket. Make sure that the remains of sealing materials do not get into the oil and coolant supply channels.
18. If no work has been carried out on the cylinder block that causes a change in the protrusion of the piston bottom, then you should use new head gasket with the same thickness marking as on the old gasket. Otherwise, the repair thickness of the gasket should be re-determined by measuring the protrusion of the bottom of all pistons relative to the plane of the cylinder block. When protruding from 0.92 to 1.03 mm use gasket with 2nd holes, and when protruding over 1.03 mm - With 3rd holes.
19. Fasten the cylinder head bolts so that they do not protrude above the mating surface of the cylinder head and carefully install it.
20. Insert all bolts of fastening of a head of cylinders and tighten them in the sequence specified on illustrations.
Cylinder head bolts No. 7-10 and No. 1-6 differ in diameter (M10 and M12).
21. Tighten the three front bolts on the cylinder head.
Right cylinder head
If the installed charge air hoses are not degreased and damp, the turbocharger may fail.
1. Press the latch (1), disconnect the plug (2) diagnostic connector and set aside.
2. Turn out bolts of fastening of a turbocharger.
When installing, clean the mating surfaces and replace the turbocharger gasket.
3. Remove both right camshafts and intake manifold (see Section Removal and installation of the inlet pipeline).
4. Remove rocker arms (1) and hydraulic lifters (2) valve clearances. Make sure the rocker rollers run smoothly.
Rocker arms, hydraulic tappets that were in operation should be installed in their original places, so when removing them, lay them accordingly.
5. Turn out three forward bolts on a head of cylinders and bolts of fastening of a head of cylinders in reverse sequences.
Bolts of fastening of heads of cylinders No. 7-10 and No. 1-6 differ in diameter. To remove the cylinder head, do not completely unscrew the #10 bolt. Bolts cannot be reused.
6. Loosen clamps (1 and 2) and remove the hose (3).
7. Turn out a bolt of fastening of a directing in a forward part of a head of cylinders (see illustration).
When installing, use new fasteners.
8. Follow the steps described in paragraphs 15 to 21.