Caution! Place the removed head on wooden blocks to avoid damaging the injectors, glow plugs and valves.
2. Disconnect the exhaust manifold together with the turbocharger, the generator mounting bracket, the lower part of the intake manifold and the engine lifting eyes from the cylinder head.
Caution: Mark all camshaft bearing caps before removing them so that they can be reinstalled in their original locations during reassembly.
3. Loosen the camshaft bearing cap bolts by turning them half a turn or a full turn in a spiral motion as shown in the illustration. After loosening all the cap bolts, remove them and remove the camshaft (see illustration).
Attention! Place the removed injectors, rocker arms and hydraulic tappets in the order they were removed so that they can be installed in their original places during assembly.
4. Unscrew bolt 1 of the fastening, lift the injector rail and remove it (see illustration).
5. Remove the rocker arms 2 of the valve drive, having previously marked their position (see illustration 5.4). The reference marks on the rocker arms in the form of arrows are located on the ends adjacent to the injector ramp.
6. Remove the sealing rings from the fuel injectors.
7. Screw the KM-931 adapter onto the fuel injectors, install the KM-328-V puller onto it, unscrew the fuel injectors and remove the heat-protective gaskets.
8. Unscrew the glow plugs using the KM-980 key.
9. Mark the valves and their mounting locations.
10. Compress the valve springs using the puller 1 KM-348 and adapter 2 KM-653-A, remove the crackers, remove the plate and springs (see illustration).
11. Using the KM-840 puller, remove the oil deflector caps and remove the support washers of the lower (outer) valve springs.
12. Clean all parts.
13. Inspect all parts and their surfaces for damage and wear.
14. Lubricate the valves with engine oil and install them in the guides on the cylinder head, following the markings made before removal.
15. Install the lower spring support washers and oil seals 1 (see illustration).
16. Install the springs and their plates, compress the springs with the KM-348 puller and the KM-653-A adapter and insert the crackers.
17. Install new sealing rings 2 and 3 on the fuel injectors and apply white sealant to them (see illustration).
18. Install the fuel injectors onto the cylinder head.
19. Screw in the glow plugs, tightening them to 10 Nm.
20. Lubricate the hydraulic tappets with engine oil and install them on the cylinder head according to the markings made before removal.
21. Install a new sealing ring 1 on the injector rail and lubricate it with a thin layer of white sealant (see illustration).
22. Install the injector rail into the cylinder head, being careful not to damage the sealing ring.
23. Secure the injector rail with a new bolt, tighten it with a wrench without a ratchet and turn it 360° (see illustration).
Attention! Only this procedure for fastening the injector rail ensures the correct fit of the rail on the injectors.
24. Install the valve rocker arms into the cylinder head, following the markings made before removal.
25. Apply black sealant to the shaded areas indicated by the arrows (see illustration).
26. Apply grey molybdenum grease to the mating surfaces of the rocker arms and camshaft and place the camshaft into the cylinder head.
27. Install the camshaft bearing caps, observing the markings made before removal, screw in their mounting bolts and tighten the bolts, acting in a spiral pattern (see illustration). First tighten all bolts by half a turn or a full turn, and then, maintaining the specified order, tighten them with a force of 15 Nm.
28. Install the lower part of the intake manifold on the cylinder head, replacing the old sealing gasket and mounting nuts with new ones. Tightening torque of the nuts is 22 Nm.
29. Connect the upper part of the intake manifold to the lower part of the cylinder head, replacing the sealing gasket with a new one and tightening the mounting bolts with a force of 8 Nm.
30. Connect the exhaust manifold to the head, replacing the sealing gasket and mounting nuts with new ones. Tightening torque of the nuts is 22 Nm.
31. Install the generator mounting bracket, replacing its seal with a new one. The tightening torque of the bracket mounting bolts is 20 Nm.
32. Screw the engine lifting eye to the head using a torque of 20 Nm.
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