Contents: Removal ↡ Installation ↡
Removal
1. Disconnect the negative cable from the battery.
2. Drain the coolant.
3. Remove the intake manifold 13 (see figure 4.15).
Figure 4.15. Cylinder head:
1, 4, 11. Bolt,
2. Spring,
3. Spring tension lever,
5. Support,
6. Sliding lever,
7, 8. Vacuum tubes,
9. Camshaft,
10. Nozzle,
12. Fuel filter,
13. Intake manifold,
14. Fuel cooler.
4. Remove injectors 10.
5. Remove the fuel lines and fuel cooler 14.
6. Unscrew bolts 11 and disconnect fuel filter 12 together with the attached pipes.
7. Remove the generator drive belt.
8. Remove spring tension lever 3 and spring 2.
9. Unscrew bolt 1 securing the damper to the cylinder head.
10. Disconnect vacuum tubes 7 and 8 from the vacuum pump.
11. Disconnect support 5 from the generator bracket.
12. Remove camshaft 9.
13. Remove sliding lever 6 from the cylinder head.
14. Disconnect the wiring connectors from glow plugs R13-R16 (see figure 4.16).
Figure 4.16. Cylinder head:
15, 16, 29. Cooling system pipes,
17. Body,
18. Heating system delivery pipe,
19. Return pipe of the heating system,
20. Bolts,
21. Cooling system pipe,
22. Front part of the exhaust system,
23. Turbocharging,
24, 25. Vacuum tubes,
26. Thermovalve,
27. Protector,
28. Cooling system pipe,
B8. Coolant temperature sensor,
R13-R16. Glow plugs,
X42. Coolant temperature sensor wiring connector.
15. Disconnect vacuum tubes 24 and 25 from thermovalve 26.
16. Disconnect the X42 wiring connector from the B8 coolant temperature sensor.
17. Disconnect cooling system pipes 15 and 16 from housing 17.
18. Disconnect the cooling system hose 29 from the cooling system pipe.
19. Remove protectors 27 and cooling system pipe 28.
20. Remove the cooling system pipe 21 from the heating system return pipe 19.
21. Unscrew bolts 20.
22. Disconnect the heating system return pipe 19 from the cooling system pump housing.
23. Disconnect the exhaust pipe 22 from the exhaust manifold.
24. Remove turbocharger 23.
25. Unscrew bolts 31 securing the timing chain drive cover.
26. Loosen and unscrew bolts 32, 33 and 34 securing the cylinder head (see figure 4.17). The order of loosening the mounting bolts is shown in the figure 4.18.
Figure 4.17. Cylinder head:
30. Cylinder head,
31. Bolt,
32, 33, 34. Cylinder head mounting bolts,
35. Cylinder head gasket,
36. Adjusting pins.
Figure 4.18. Procedure for loosening the cylinder head mounting bolts
27. Check the cylinder head mounting bolts and replace them if necessary.
28. Remove the cylinder head 30. Wipe the contact and threaded surfaces, check for damage.
Installation
29. Installation is carried out in the reverse order of removal. Replace cylinder head gasket 35 and make sure it is installed on adjusting pins 36 correctly. The tightening order of the cylinder head mounting bolts is shown in the figure 4.19.
Figure 4.19. Cylinder head bolt tightening sequence
30. Lubricate the threaded portion and the bearing surface of the cylinder head.
31. Replace the heating system return pipe retainer 19.
32. Spring 2 is installed with the color mark facing up.