Contents: Removal ⬇ Installation ⬇
Removal
1. Place the vehicle on a four-post lift.
2. Disconnect the battery. The battery is located under the left seat, so you need to remove the floor mat by detaching the clips holding it, then the battery cover A by unscrewing the bolts (figure 3.22).
3. Drain the coolant by disconnecting the hose from the radiator.
4. Remove the timing belt, heater radiator B, disconnecting the wiring connector 1 (figure 3.37).
Figure 3.37. Remove the timing belt, heater radiator B, disconnect wiring connector 1.
5. Remove the air filter housing, disconnect the vacuum hoses 2 (figure 3.38).
Figure 3.38. Remove the air filter housing, disconnect the vacuum hoses 2.
6. Disconnect the supercharging system pipeline C, wiring harness 3, as well as the wiring connectors from the injectors and glow plugs, unscrew the mounting bolt 4 of the immersion heater housing, the fuel drain line at point 5 (plug the holes with protective plugs) (figure 3.39).
Figure 3.39. Disconnect the supercharging system pipeline C, wiring harness 3, as well as the wiring connectors from the injectors and glow plugs, unscrew the mounting bolt 4 of the immersion heater housing, the fuel drain line at point 5.
7. Disconnect the hoses from the thermostat unit located on the coolant return line from the cylinder head and the coolant temperature sensor wiring connector (figure 3.40).
Figure 3.40. Disconnect the hoses from the thermostat unit located on the coolant drain line from the cylinder head and the coolant temperature sensor wiring connector.
8. Disconnect the vacuum pipe from the brake booster.
9. Disconnect the fuel line 1 (plug the holes with protective plugs), and also wiring connector 2 (figure 3.41).
10. Disconnect the wiring connectors 3, as well as the TDC sensor 4 (figure 3.42)
Figure 3.41. Disconnect fuel line 1 (plug the holes with protective plugs), and also wiring connector 2.
Figure 3.42. Disconnect wiring connectors 3 and TDC sensor 4.
11. Disconnect the exhaust system inlet pipe fastening parts.
12. Disconnect the air duct A, as well as the turbocharger outlet air duct, then move it to the side, disconnect supports 5 and 6, then the catalyst 7 (figure 3.43).
Figure 3.43. Disconnect air duct A, as well as the turbocharger air outlet duct, then move it to the side, disconnect supports 5 and 6, then catalytic converter 7.
13. Disconnect the oil drain line 1, unscrew the mounting bolt 2, unscrewing the oil line at point 3, then remove the oil pressure line at point 4 and move it to the side of the engine compartment bulkhead (figure 3.44).
Figure 3.44. Disconnect the drain oil line 1, unscrew the mounting bolt 2, unscrewing the oil line at point 3, then remove the pressure oil line at point 4 and move it to the side of the engine compartment bulkhead.
14. Unscrew the cylinder head mounting bolts and remove it together with the gasket.
Checking the cylinder head deformation
15. Using a straightedge and a set of feeler gauges, check for deformation of the contact surface of the cylinder head. Maximum permissible deformation: 0.05 mm.
Attention! Grinding of the cylinder head is not permitted.
16. Check the cylinder head for possible cracks using a cylinder head leak tester (consisting of a container, a set corresponding to the cylinder head, a plug, a sealing plate, a plug).
Installation
17. Install the cylinder head gasket. The gasket is centered by two forks. Set the pistons to mid-stroke to prevent the pistons from touching the valves when tightening the head bolts. Center the cylinder head on the mounting bushings. Apply oil to the threads and underside of the head bolts. Tighten the cylinder head mounting bolts using an angle wrench.
18. Further installation is carried out in the reverse order of removal.
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