Special tool
 | Engine lift bracket 303-122 (21-068A) |
 | Protractor for tightening bolts 303-174 (21-540) |
 | Clamp remover/installer 303-397 (24-003) |
| Name | Specification |
| Engine oil | WSS-M2C912-A1 |
| Loctite 7070 |
Withdrawal
All cars
1.
WARNING: Do not smoke or walk with a lit cigarette or any type of open flame while working on or near fuel related items. In such situations, there are always highly flammable mixtures that can ignite. Failure to follow these instructions may result in injury.
CAUTION: Diesel fuel injection equipment is manufactured to very precise tolerances and very close clearances. Therefore, it is especially important to observe absolute cleanliness when working with these elements. Always insert plugs into any open holes or lines.
Remove the battery and battery tray. See Section 414-01 for more information.
2. Drain the coolant from the cooling system. See Section 303-03 for more information.
3. Remove the timing belt. For more information, refer to the Timing Belt chapter found in this section.
4. Remove the pulley from the camshaft.
5. Disconnect the rear timing belt cover (for clarity, the engine is shown removed).
Vehicles manufactured up to 04.2001
6. Install the front engine mount.
Vehicles manufactured since 04.2001
7. Install the front engine mount.
All cars
8. Remove special tools.
9. Remove the air filter. See Section 303-12 for more information.
10. Remove the final pipeline of the air filter.
11. Disconnect the vacuum hose from the vacuum diaphragm unit.
12. Remove the oil separator.
13. Establish nuts of covers of bearings of camshafts.
14. Raise and support the vehicle. See Section 100-02 for more information.
15. Disconnect the catalytic converter from the appropriate bracket.
16. Disconnect the turbocharger supply and return oil lines. Discard the gasket as it is no longer needed.
17. Lower the car.
18. Disconnect the plug connector of the oil pressure switch.
19. Remove the oil separator.
20. Disconnect the high pressure pipe from the power steering pump. Let the liquid drain into a suitable container.
21. Disconnect the power steering high pressure pipe bracket from the timing belt cover stud.
22. Disconnect the power steering high pressure pipe bracket from the engine lift lug.
23. Disconnect the power steering high pressure line from the bracket and position it aside.
24. Disconnect the glow plug power wire from the glow plug wire terminal block.
25. Disconnect the glow plug wire terminal block.
26. Disconnect the dipstick of the oil level indicator and secure it to the side.
27. Disconnect the vacuum pipeline from the vacuum pump of the vacuum amplifier of brakes.
28. Using the special tool, disconnect the upper coolant hose from the thermostat housing.
29. Remove the thermostat housing. Discard the gasket as it is no longer needed.
30. Disconnect the high pressure fuel lines from the high pressure fuel pump.
31. Remove the high pressure fuel lines. Discard fuel lines as they are no longer needed
32. Disconnect the power steering fluid reservoir and secure it to the side
33. Disconnect the exhaust manifold from the catalytic converter. Discard the nuts as they are no longer needed.
34. Using the special tool, disconnect the upper coolant hose from the EGR cooler (EGR).
35.
CAUTION: Remove the cylinder head bolts in the sequence shown.
Turn out bolts of a head of cylinders. Discard the bolts as they are no longer needed.
36. Using the special tool, remove the cylinder head. Discard the gasket as it is no longer needed.
Installation
All cars
1. Clean mating surfaces of cylinder head and cylinder block using Loctite 7070.
2. Check up a head of cylinders on existence of deformation of an interfaced surface. See Section 303-00 for more information.
3.
CAUTION: The thickness of the new cylinder head gasket must match the thickness of the «old» (hole/prong markings).
NOTE: Marking «TOP/OBEN» («Up»).
Install a new cylinder head gasket.
4.
NOTE: Make sure the special tool fits into the groove on the end of the camshaft.
Install the cylinder head to the cylinder block using the special tool when installing. Remove the special tool.
5.
CAUTION: Use new, unlubricated cylinder head bolts.
Tighten the cylinder head bolts in four stages.
- Using the special tool, tighten the bolts in the sequence shown.
- Stage 1: 20 Nm
- Stage 2: 54 Nm
- Stage 3: 90 degrees
- Stage 4, short bolts: 70 degrees.
- Stage 4, long bolts: 90 degrees.
6. Using the special tool, connect the upper coolant hose to the EGR cooler.
7.
NOTE: Use new catalytic converter nuts.
Connect the exhaust manifold to the catalytic converter.
8. Fix a tank of a working liquid of the amplifier of a steering.
9.
NOTE: Use new high pressure fuel supply lines.
Connect the high pressure fuel lines to the fuel injectors.
10. Connect the high pressure fuel feed lines to the high pressure fuel pump.
11.
NOTE: Use a new gasket.
Install the thermostat housing.
12. Using the special tool, connect the upper coolant hose to the thermostat housing.
13. Connect the vacuum pipeline to the vacuum pump of the vacuum amplifier of brakes.
14. Connect the dipstick for the oil level indicator.
15. Connect the glow plug wire terminal block.
16. Connect the glow plug power wire to the glow plug wire terminal block.
17. Connect the power steering high pressure line to the bracket.
18. Connect the power steering high pressure pipe bracket to the lift lug.
19. Connect the power steering high pressure pipe bracket to the timing belt cover stud.
20. Connect the high pressure line to the power steering pump.
21. Connect the plug connector of the oil pressure switch.
22.
NOTE: Set the clamp at a 45 degree angle to the horizontal.
Install the oil separator.
23. Raise and support the car. See Section 100-02 for more information.
24.
NOTE: Use a new gasket.
Connect the turbocharger supply and return oil lines.
25. Connect the catalytic converter to the appropriate bracket.
26. Lower the car.
27. Remove the camshaft bearing cap nuts.
28. Install the oil separator.
29. Connect the vacuum hose to the vacuum diaphragm assembly.
30. Install the air filter outlet pipe.
31. Install the air filter. See Section 303-12 for more information.
32. Install special tools.
Vehicles manufactured up to 04.2001
33. Remove the front engine mount.
Vehicles manufactured since 04.2001
34. Remove the front engine mount.
All cars
35. Connect the rear timing belt cover (for clarity, the engine is shown removed).
36.
NOTE: Do not tighten the camshaft pulley bolt at this stage.
Install the camshaft pulley.
37. Install the timing belt. For more information, refer to the Timing Belt chapter found in this section.
38. Fill in cooling liquid in the cooling system and remove air from the system. See Section 303-03 for more information.
39. Add working fluid to the power steering system and remove air from the system. See Section 211-00 for more information.
40. Install the battery tray and install the battery. See Section 414-01 for more information.
41. Change engine oil and oil filter.
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