Warning! Be careful not to get dirt into the fuel pump.
When installing the cylinder head, upper guides and camshaft sprocket, new bolts must be used. The location of the coolant supply hoses in the front of the cylinder head
Arrangement of bolts of fastening of a cover of a chain to a head of the block of cylinders and one bolt of fastening of a head to the block of cylinders
Removing
1. Drain the coolant from the cooling system.
2. Remove a wire of weight from the accumulator and a cover of a head of the block of cylinders.
3. Remove the brake vacuum pump.
4. Set the piston of the first cylinder to top dead center on the compression stroke and fix the crankshaft.
5. To improve access to the fuel pump sprocket cover, do the following:
- remove the air filter cover and front exhaust pipe;
- remove the auxiliary drive belt;
- unscrew the mounting nut from the power unit suspension frame and raise the engine so as not to deform the hoses and pipes.
6. Remove the upper chain tensioner.
7. Remove the drive belt tensioner.
8. Unscrew bolts and remove a cover of an asterisk of the fuel pump.
9. Apply alignment marks between the top chain and sprockets, and between the camshaft sprocket and camshaft.
10. Unscrew the bolts and remove the upper chain guide.
11. Before loosening the top chain guide mounting bolts, the bolts must be heated to soften the loosening compound.
12. Using a wrench, fix the camshaft from turning and unscrew the bolts securing the camshaft sprocket. Before unscrewing the bolt, remove the crankshaft lock pin and after unscrewing the bolt, install the pin in place.
13. Remove the chain from the camshaft sprocket and remove the sprocket from the engine. Place a screwdriver or steel rod under the chain to prevent it from falling into the cylinder head.
14. Clean the area near the connection of the fuel supply pipe to the fuel pump and unscrew the pipe fastening bolts (indicated by arrows). Disconnect the return pipe from the fuel pump. Disconnect the pipes from the mounting brackets and move them away from the cylinder head.
15. Remove the intake and exhaust manifolds. If disassembly of the cylinder head is not required, it can be removed together with the manifolds after performing the following steps:
- on turbo models, disconnect the intake ports and metal pipe from the turbocharger;
- unscrew the bolt securing the wiring harness to the top of the intake manifold and disconnect the electrical connectors;
- disconnect the electrical connector from the crankshaft sensor;
- disconnect the pipes from the fuel injectors;
- disconnect the vacuum hoses from the intake manifold switch and EGR valve;
- disconnect the electrical wires from the glow plugs and remove the turbocharger heat shield;
- disconnect the turbocharger oil lines from the cylinder block, disconnect the damper diaphragm vacuum hose;
- remove the starter heat shield.
16. Loosen the clamps and disconnect the coolant supply hoses to the cylinder head.
17. Unscrew the top bolt of fastening of the generator and move the generator from a head of the block of cylinders.
18. Remove the three bolts securing the right end of the cylinder head to the top of the chain cover and one bolt securing the cylinder head to the cylinder block.
19. Gradually and sequentially, in reverse order, unscrew the 10 cylinder head bolts.
20. Remove the cylinder head bolts with washers.
21. Remove the cylinder head. Remove the cylinder head gasket.
Warning! Do not lay the cylinder head on the bottom of the table, but only on wooden blocks, as fuel injectors and glow plugs protrude from the cylinder head.
Preparing for installation
1. The mating surfaces of the engine head and cylinder block must be thoroughly cleaned of gasket residue and carbon deposits using a plastic or wooden scraper. It is also necessary to clean the tops of the pistons. When cleaning, exclude the possibility of getting cleaning products into the oil channels of the cooling system. Thoroughly clean the inner surfaces of the cylinders.
2. Check the mating surfaces of the engine head and cylinder block for defects. Minor damage is eliminated by machining. Also using a metal ruler and feeler gauge, check the flatness of the surfaces.
3. Clean the bolt holes in the block. Screwing a bolt into an oil-filled hole can rupture the block due to hydraulic pressure.
4. Depending on the amount of protrusion of the pistons from the cylinder block, it is necessary to use a head gasket of a strictly defined thickness. Gasket thickness identified by holes punched in the left front corner of the gasket (see table N1).
5. Check that the crankshaft is at top dead center on the #1 piston. Install the dial gauge on the bracket to the cylinder block. Install a measuring tip on the cylinder block and set the indicator scale to 0. Place a measuring tip on the piston of the first cylinder and turn the crankshaft slightly in both directions and note the highest value on the indicator. Write down this value.
6. Measure the piston protrusion on cylinder N4 in the same way. Then turn the camshaft 180°and repeat the piston protrusion measurement on cylinders 2 and 3. Rotate the camshaft 540°and return it to its original position.
7. Using the maximum piston protrusion, select the cylinder head gasket (see table N2).
Table N1
Number of holes
|
Gasket thickness
|
without hole
|
1.20 mm
|
1 hole
|
1.30 mm
|
2 holes
|
1.40 mm
|
3 holes
|
1.50 mm
|
Table N2
Piston protrusion
|
Gasket thickness
|
0.40 - 0.50 mm
|
1.20 mm
|
0.51 - 0.60 mm
|
1.30 mm.
|
0.61 - 0.70 mm
|
1.40 mm
|
Installation
1. Wipe mating surfaces of cylinder block and cylinder head.
2. Check that the two guide pins are installed in the cylinder head and install the cylinder head gasket.
3. Check that the crankshaft is locked at top dead center on the first cylinder on the compression stroke and that the lobes of the first cylinder camshaft are pointing up and the groove on the left side of the camshaft is parallel to the surface of the cylinder head.
4. Install the cylinder head. Remove the top chain to the top of the cylinder head and secure it to the head using a screwdriver blade or steel rod.
5. Lubricate the cylinder head bolts with engine oil, insert them into the head and tighten by hand.
6. Tighten the cylinder head bolts gradually and sequentially in several stages.
7. Install the chain cover bolts to the right side of the cylinder head.
8. Rotate the alternator towards the engine and secure the upper alternator mounting bolt.
9. Connect the cylinder head coolant hoses and secure with clamps.
10. Install the intake and exhaust manifolds.
11. Install the camshaft sprocket onto the camshaft.
12. Install the fuel lines with new washers and tighten them to the correct torque.
13. Pour coolant into the engine cooling system.
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