2. Remove the air filter housing.
3. Drain the coolant.
4. Loosen the screw (1) attaching the turbocharger to the bottom of the exhaust manifold.
5. Remove fastening EGR. (Only for motors with code MS3. Engine version: Euro 3.)
6. Remove the air manifold.
7. Remove the decorative cylinder head panel.
8. Disconnect clamps (2).
9. Disconnect the hose (3) coolant from the radiator.
10. Disconnect the ventilation hose (4) from the expansion tank.
11. Remove catalytic converter temperature sensor (Only for engines with code KA 1: presence of a diesel particulate filter from 25.9.06.)
12. Remove the hose (5), connecting the engine to the intake duct, together with the ventilation hose (6). To do this, remove the clamp from the turbocharger pipe and disconnect the sensor connector (14) air filter outlet pressure. Disconnect the ventilation hose (6) from the oil separator.
13. Disconnect the wiring harness, marking the connection points of the connectors.
14. Disconnect the fuel return line from the injectors.
15. Remove the vacuum pump (17), by unscrewing the screws (16).
16. Remove vacuum accumulator (7). (Only for engines 646.982/983.)
17. Set aside as far as possible the vacuum tubes (8) with vacuum accumulator (7).
18. Remove the high pressure fuel pump (further - high pressure fuel pump) (see fig. VN 2.041).
19. Remove the screw (11).
20. Remove bracket (12).
21. Remove the clamp and disconnect the fuel return line.
VN 2.040
Removing the cylinder head
1. Screw
2. Clamps
3. coolant hose
4. Ventilation hose
5. Duct
6. Crankcase ventilation hose
7. Vacuum accumulator
8. Main vacuum tube
9. Hose
10. Brackets
11. Screw
12. Brackets
13. Screw
14. Air filter outlet pressure sensor (Q28/5)
15. Vent line heater (R39/1)
Removing the vacuum pump
16. Screw
17. Vacuum pump
VN 2.041
Removal of injection pump
1. Vacuum pump
2. High pressure fuel line
3. injection pump
4. Fuel lines
5. Screws
6. O-ring
7. Drive roller injection pump
8. Fuel temperature sensor (B50 or B50/3)
9. Fuel control valve (Y94 bkb Y94/3)
VN 2.042
1. High pressure fuel lines supplying fuel to the injectors
2. High-pressure fuel line for fuel supply to the TKVD
3. Screw
4. Banjo bolt connector
5. Pressure sensor in TKVD (В4/6)
6. Fuel pressure control valve (Y74)
7. Screw fastening TKVD
8. Fuel return line
VN 2.043
Removing nozzles
1. Impact puller
2. Screw rod of impact puller
3. Thread adapter
4. Camshaft position sensor (B6/17)
23. Take the cylinder head wiring harness to the side.
24. Remove nozzles (see fig. VN 2.043).
When installing the clamp screw, tighten according to the scheme 7 Nm + 90°+ 90°.
25. Remove the oil filler tube (2) automatic transmission (only with automatic transmission) (see fig. VN 2.044).
26. Disconnect the coolant hose (1) from the cylinder head, for which loosen the clamp (4), and move the hose aside.
27. Loosen the screw (5) oil dipstick guide tube clamp (6).
28. Remove the oil supply pipe to the turbocharger (see fig. VN 2.045).
29. Loosen the screws (13) (see pic, VN 2.040) attaching the turbocharger to the exhaust manifold.
30. Check the correctness of the initial settings of the camshafts (see fig. VN 2.046) To do this, check the relative position of the camshafts and the mutual position of the crankshaft and the camshaft system.
VN 2.044
Removing the MCC (shown on engine 646.982 from number 007338)
1 coolant hose
2. Oil filler pipe automatic transmission
4. Clamp
5. Screw
6. Oil dipstick guide tube
7. Screws
8. MCC fixing screws
VN 2.045
Removing the oil supply pipe to the turbocharger
1. Engine air inlet
2. Oil supply line
3. Clamp
4, 5. Screws
6. Spigot
7. Air filter outlet pressure sensor (828/5)
8. Vent line heater (R39/1)
VN 2.046
1. Crankshaft pulley
2. Inlet camshaft
3. The pin that fixes the position of the gear of the intake camshaft
4. Camshaft bearing
5. Gear marks