Attention! When working on cooling, fuel supply and lubrication systems, it is necessary to protect the generator from contamination by covering it with a dense polyethylene film. Failure to do so may result in generator failure.
The charge air hoses to be installed must be free of grease, dry and clean.
Replacement of a head of the block of cylinders is necessary for carrying out in a following order. Prepare fixtures «00.2.530», «00.9.120», «11.2.300», «11.3.340», «11.6.321», «11.6.322», «11.6.480», «13.5.020» And «11.6.050» and put the car horizontally. Disconnect «negative» battery terminal and remove the cylinder head cover.
Remove the A/C compressor drive belt and alternator drive belt, cover the alternator with plastic wrap. Drain the coolant and send it for recycling. Remove vacuum pump.
Remove the engine accessory protection panels. Remove heat exchanger hoses (air-to-air radiator) turbocharger and remove the engine. Remove right engine mount bracket and exhaust manifold with TC.
Fix the engine with the tool «11.8.040» at the assembly stand «00.1.490». It is allowed to use a modified device «11.3.350». In the absence of an assembly stand, install the engine on a workbench, remove the vacuum pump and the engine bottom shields.
Loosen the screws securing the TC bracket. Loosen the bolts (arrows, fig. 6.65) and disconnect the TC from the exhaust manifold.
Remove bolts (3, fig. 6.66) on the back of the cylinder head. Remove the cylinder head cover and camshafts.
Attention!
- To avoid damage to the valves during the subsequent installation of the camshafts, none of the pistons should be at TDC.
- The levers of the pushers that were in operation are installed only in their places.
- On the removed cylinder head, the glow plugs protrude above the surface of the head, use stands (bars).
- fixtures «11.6.050», issued before April 1998, ream with a drill with a diameter of 9.5 mm to a depth of 20 mm.
- Install new cylinder head bolts and cylinder head gasket each time.
Remove all levers (1, fig. 6.67) pushers and put them in order. Remove all compensators (2) and put them in order.
Loosen the front screws (1, fig. 6.68) timing cover fasteners.
Unscrew the cylinder head bolts from the edges to the middle, in the sequence of numbering 14 - 1 (pic. 6.69). Remove the cylinder head and place it on a support without damaging the protruding glow plugs. If necessary, the glow plugs can be removed (turned inside out) adaptation «11.6.050», manufactured after April 1998, or a modified fixture - a 9.5 mm reamed drill to a depth of 20 mm.
Remove seal (1, see fig. 6.3) cylinder head, paying attention to the marking of its thickness (number of holes).
Installation of the cylinder head should be carried out in the reverse order, while the following features must be taken into account.
Clear docking (compacted) the surface of the cylinder block and cylinder head from compaction residues with a hardwood scraper (beech, hornbeam, oak). Seal residues must not get into the oil and coolant channels.
Using compressed air, clean all blind threaded holes of oil and coolant.
If no work has been done on the crank mechanism or pistons on the engine block, causing changes in the protrusion of the piston crown, then a new head gasket with the same thickness marking should be used (number of holes), as the previous gasket.
After carrying out work that causes changes in the protrusion of the piston crown above the mating surface of the cylinder block, it is necessary to re-determine the thickness of the sealing gasket (see below).
The joints between the timing case cover and the cylinder block are sealed using sealing strips glued as standard, and additional sealant is not required in these places. Check the technical condition of the centering sleeve, replace it if necessary. Transitions must be absolutely free of grease. Always install a new cylinder head gasket.
Carefully place the cylinder head on the block. Install new cylinder head bolts (washed and lubricated with engine oil) until they touch the head. Tighten new cylinder head bolts in sequence 1-14 (pic. 6.69) in five steps:
- 1st step, tighten to 80 Nm (8.0 kgf·m);
- 2nd reception, loosen by half a turn (180°);
- 3rd step, tighten to 50 Nm (5.0 kgf·m);
- 4th reception, tighten by an angle of 90°;
- 5th reception, tighten another 90°.
When turning to a given angle, use the tool «00.9.120». Tighten the bolts (1, see fig. 6.68) timing covers.
Lubricate with engine oil the bed and camshaft bearing caps. Install the hydraulic lifters and pusher levers in their places. Lay the valve drive camshafts, taking into account that the exhaust camshaft is marked «A» (pic. 6.70), and inlet - «E». Marks are applied on the body of the shaft in the area between the cams of the 1st and 2nd cylinders.
Install bearing caps. The bearing caps of the exhaust camshaft drive are marked - «A1–A7», and intake valves - «E1–E7».
Install the TC on the exhaust manifold, replacing the gasket and lubricating the threads with a copper-containing paste of the type «CRC» or «Molykote-HSC». Tighten the bolts (M10) fixing the fuel tank to the exhaust gas manifold with a torque of 50 Nm (5.0 kgf·m). Tighten glow plugs to 18 Nm (1.8 kgf·m). Assemble the engine.