Preliminary Operations
1. Disconnect and remove the battery.
2. Drain coolant and engine oil.
3. Disconnect and remove the air filter elements.
4. Remove the throttle body (see fig. M2 2.058).
5. Disconnect and remove elements of the EGR system (see fig. M2 2.059).
Removal of elements of the EGR system: 1. Latch-holder of the harness; 2. Oil dipstick with tube assembly; 3. O-ring; 4. Transmission oil level dipstick with tube assembly; 5. O-ring; 6. EGR valve connector; 7.EGR valve; 8. EGR valve gasket; 9. Pipe gasket; 10. Spigot «IN» EGR valve; 11. Pipe gasket; 12. Thermal protection screen; 13. Pipe «A» EGR valve; 14. Pipe gasket; 15. Pipe gasket; 16. Rods of the cooling system; 17. Heater hose; 18. EGR exhaust gas cooler; 19. Cooler mounting bracket
* Removal of elements is carried out in the order of the numbers indicated in the figure
6. Disconnect and remove the intake manifold elements (see fig. M2 2.060).
Removing intake manifold elements: 1. Electrical connectors for injectors; 2. Electrical connector for the inlet air temperature sensor; 3. Electrical connector fuel pressure sensor; 4. Wire glow plugs; 5. Latch-holder of the harness; 6. Latch-holder of the battery cable; 7. Battery cable terminal «weight»; 8. Vacuum hose and tube assembly; 9. Vacuum hose and tube assembly; 10. Hose of the vacuum brake booster; 11. Vacuum tube «IN»; 12. Vacuum hose; 13. Vacuum tube «A»; 14. Engine cover bracket; 15. Fuel hose «D»; 16. Fuel line; 17. Intake manifold bracket; 18. Intake manifold assembly; 19. Intake manifold gasket; 20. Intake manifold gasket; 21. Inlet air temperature sensor; 22. Gasket
* Removal of elements is carried out in the order of the numbers indicated in the figure
7. Disconnect and remove the valve cover and fuel injector housings (described above).
8. Remove the fan impeller assembly with clutch, covers and timing belts (described above).
9. Disconnect and remove elements of the fuel injection system (see fig. M2 2.061).
Removal of elements of the fuel supply and injection system: 1. Injection pump pulley; 2. Fuel return hose; 3. Fuel supply hose; 4. High pressure tube (TNVD-TKVD); 5. HPFP assembly; 6. High pressure pipes (TKVD nozzles); 7. Banjo bolt; 8. Gasket; 9. Fuel manifold (TKVD) assembled; 10. Banjo bolt; 11. Gasket; 12. Fuel return pipe
* Removal of elements is carried out in the order of the numbers indicated in the figure
10. Disconnect and remove the turbocharger and exhaust manifold (see fig. M2 2.062).
Removing the turbocharger and exhaust manifold: 1. Lubrication system tube; 2. Gasket; 3. Coolant tube «IN»; 4. Gasket; 5. Coolant hose; 6. Coolant tube "WITH"; 7. Gasket; 8. Coolant hose; 9. Oil return pipe to the lubrication system; 10. Pipe gasket; 11. Pipe gasket; 12. Turbocharger assembly; 13. Turbocharger gasket; 14. Thermal protection screen; 15. Bracket; 16. Exhaust manifold; 17. Manifold gasket
* Removal of elements is carried out in the order of the numbers indicated in the figure
11. After carrying out all the preliminary work, remove the cylinder head (see fig. M2 2.063).
Removing the cylinder head: 1. Connector of the emergency temperature sensor 0Ж; 2. Connector coolant temperature gauge; 3. Terminal for connecting glow plugs; 4. Upper radiator hose; 5. Branch pipe of the oil line; 6. Camshaft drive pulley; 7. Rear timing belt cover; 8. Power steering pump assembly; 9. Cylinder head screws; 10. Cylinder head assembly; 11. Cylinder head gasket
* Removal of elements is carried out in the order of the numbers indicated in the figure
Removing the camshaft pulley
1. Holding the camshaft with tools (1) And (2), unscrew the fastening nut and remove the gear.
Note: when installing the pulley, holding it with tools, tighten the fastening screw with a torque of 88±10 Nm.
Removing the steering oil pump
Note: Power steering pump (8) (see fig. M2 2.063) removed as an assembly without disconnecting the corresponding lines.
Removing cylinder head screws
Head screws are unscrewed in pairs (with a weakening in two or three doses), in accordance with the numbering shown in the figure (see fig. M2 2.065).
Note: Before removing the screws, mark the head of each screw with a punch. Apply one mark each time you loosen the screws and remove the cylinder head.
When the number of marks reaches five, the screw must be replaced with a new one, even if its length corresponds to the nominal value.
The nominal length of the cylinder head mounting screws is no more than 93 mm.