Contents: M628 ↡ Timing Belt Cover (612 series…↡
612 Series Engine Front Cylinder Head Cover Installation Details
1. The installation details of the 612 Series engine cylinder head front cover are shown in the illustration to which all references in the text refer.
2. Remove the cylinder head (3) (see Section Removal and installation of cylinder head(s)).
3. Remove the chain tensioner (9) (see Section Removal and installation of timing drive components).
4. Remove the fuel pre-pump (13) (see Chapter Removal and installation the fuel pre-pump).
5. Remove the screws securing the front cylinder head cover (5).
6. Using a screwdriver, lift the ratchet (7) locking the upper chain guide (8).
Note: The guide will remain in the timing case.
7. Pull forward to remove the front cylinder head cover (5), being careful not to drop the guide pins.
8. Before installation, thoroughly clean the mating surfaces of the front cover and cylinder head.
9. Apply sealant to the mating surface of the cover.
10. Installation is carried out in the reverse order. Make sure that all fasteners are tightened to the required force.
11. Finally, start the engine and check it for signs of developing leaks.
M628
628 Series Engine Cylinder Head Front Cover Installation Details
1. The installation details of the 628 Series engine cylinder head front cover are shown in the illustration to which all references in the text refer.
2. Air distribution sleeve.
3. Release and move aside the air intake pipe of the booster tract.
4. Remove the injectors (Y76) of the right bank of cylinders.
5. Remove the cover (5) of the right cylinder head.
6. Remove the bypass hose of the air boost tract.
7. Disconnect from the engine block (above the generator) glow plug wiring support bracket.
8. Remove the vacuum pump (1)
9. Remove the high pressure fuel pump (HPFP) (2).
10. Loosen the mounting screws and pull forward to remove the front cover (3).
11. Before installation, thoroughly clean the mating surfaces of the front cover and cylinder head.
12. Apply sealant to the mating surface of the cover.
13. Installation is carried out in reverse order.
14. Make sure all fasteners are tightened to the required torque.
15. Finally, start the engine and check it for signs of developing leaks.
Timing Belt Cover (612 series engines only)
Timing Belt Cover Installation Details for 612 Series Engines
Timing Belt Cover Installation Details for 612 Series Engines
Timing Belt Cover Installation Details for 612 Series Engines
1. The installation details of the timing cover on the 612 series engine are shown in the illustrations to which all references in the text refer.
2. Open the hood and fix it in a vertical position.
3. Disconnect the negative cable from the battery.
4. Remove the lower section of sound insulation.
5. Drain the cooling system (see Chapter Checking the cooling system and frost resistance of the coolant, replacing the liquid).
6. Drain the engine oil (see Chapter Changing engine oil and oil filter).
7. Remove the cylinder head cover trim panels (3 and 4).
8. Disconnect the cooling system hoses (30 and 31).
9. Remove the air intake sleeve (4/2).
10. Remove the air boost tract sleeve (110/6) together with the hose (9) connected to it.
11. Remove the electric cooling fan (10).
12. Remove the injectors (Y76) (see Chapter Removal and installation of fuel distribution line and injectors).
13. Remove the cylinder head cover (5).
14. Turning the crankshaft in the normal direction, bring the piston of the first cylinder to the TDC position - the marks on the camshaft and its bearing cap should align.
15. Using the special tool (03), lock the flywheel/drive disk ring gear.
16. Remove the chain tensioner (22) (see Section Removal and installation of timing drive components).
17. Release the guide on the bracket.
18. Remove the thermostat (see Chapter Cooling, heating and air conditioning systems).
19. Remove the front cover (7) of the cylinder head (see above).
20. Remove the accessory drive belt (see Chapter Engine).
21. Disconnect the electrical wiring from the A/C compressor (12).
22. Unbolt the compressor (12) and, without disconnecting the refrigeration lines, move it to the side.
23. Disconnect the cooling lines connected to the liquid heat exchanger of the lubrication system (see Section Maintenance of the lubrication system).
24. Disconnect the hoses (17 and 18) from the water pump (19).
25. Remove the water pump (19) (see Chapter Cooling, heating and air conditioning systems).
26. Remove the air boost duct sleeve (21).
27. Unscrew the bolts (24) securing the oil pan from the timing cover side, only loosen the other oil pan bolts.
28. Unscrew the M8 bolts (25) securing the timing belt cover to the cylinder head.
29. Remove the timing belt cover.
30. If the timing chain needs to be replaced, remove the accessory drive belt tensioner.
31. If the cover is to be replaced, remove the liquid heat exchanger of the lubrication system.
32. Clean the mating surfaces thoroughly.
33. Apply sealant to the mating surface of the cover.
34. Installation is carried out in the reverse order - do not forget to put the guide pins back in place.
35. Finally, check the engine for signs of developing fluid leaks (oil, fuel, coolant, A/C refrigerant, etc.). Also clear the memory of the on-board diagnostic module (see Chapter Engine electrical systems).