Special tool
 | Engine lift bracket 303-122 (21-068A) |
 | Bolt Tightening Angle Gauge 303-174 (21-540) |
 | Clamp removal/installation tool 303-397 (24-003) |
| Name | Specification |
| Motor oil | WSS-M2C912-A1 |
| Loctite 7070 |
Removal
All cars
1.
WARNING: Do not smoke or carry a lighted cigarette or open flame of any type when working with or near fuel-related items. Highly flammable mixtures are always present in such situations and may ignite. Failure to follow these instructions may result in injury.
CAUTION: Diesel fuel injection equipment is manufactured to very precise tolerances and with very small clearances. Therefore, it is especially important to maintain absolute cleanliness when working with these components. Always plug any open ports or lines.
Remove the battery and battery tray. For additional information, refer to Section 414-01.
2. Drain the coolant from the cooling system. Refer to Section 303-03 for additional information.
3. Remove the timing belt. For more information, refer to the Timing Belt chapter in this section.
4. Remove the pulley from the camshaft.
5. Disconnect the rear timing belt cover (the engine is shown removed for clarity).
Cars manufactured up to 04.2001.
6. Install the front engine mount.
Cars manufactured since 04.2001.
7. Install the front engine mount.
All cars
8. Remove the special tools.
9. Remove the air cleaner. For additional information, refer to Section 303-12.
10. Remove the air cleaner outlet pipe.
11. Disconnect the vacuum hose from the vacuum diaphragm unit.
12. Remove the oil catch can.
13. Install the camshaft bearing cap nuts.
14. Raise and support the vehicle. Refer to Section 100-02 for additional information.
15. Disconnect the catalytic converter from its bracket.
16. Disconnect the turbocharger feed and return oil lines. Discard the gasket as it is no longer needed.
17. Lower the vehicle.
18. Disconnect the oil pressure switch connector.
19. Remove the oil separator.
20. Disconnect the high pressure line from the power steering pump. Allow the fluid to drain into a suitable container.
21. Disconnect the power steering high pressure line bracket from the timing belt cover stud.
22. Disconnect the power steering high pressure line bracket from the engine lifting eye.
23. Disconnect the power steering high pressure line from the bracket and place it aside.
24. Disconnect the glow plug power supply wire from the glow plug wire terminal block.
25. Disconnect the glow plug wire terminal block.
26. Disconnect the oil level indicator dipstick and secure it to the side.
27. Disconnect the vacuum line from the brake booster vacuum pump.
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 supply lines from the high pressure fuel pump.
31. Remove the high pressure fuel supply lines. Discard the 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 exhaust gas recirculation (EGR) cooler.
35.
CAUTION: Remove the cylinder head bolts in the sequence shown.
Remove the cylinder head bolts. Discard the bolts as they are no longer needed.
36. Using a special tool, remove the cylinder head. Discard the gasket as it is no longer needed.
Installation
All cars
1. Clean the mating surfaces of the cylinder head and cylinder block using Loctite 7070.
2. Inspect the cylinder head for mating surface distortion. Refer to Section 303-00 for additional information.
3.
CAUTION: The thickness of the new cylinder head gasket must match the thickness of the "old" one (marked with holes/teeth).
NOTE: Marked "TOP/OBEN".
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 on the cylinder block using the special tool during installation. Remove the special tool.
5.
CAUTION: Use new, non-greased 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. Secure the power steering fluid reservoir.
9.
NOTE: Use new high pressure fuel supply lines.
Connect the high pressure fuel supply lines to the fuel injectors.
10. Connect the high pressure fuel supply 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 line to the brake booster vacuum pump.
14. Connect the oil level indicator dipstick.
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 line bracket to the lifting eye.
19. Connect the power steering high pressure line bracket to the timing belt cover stud.
20. Connect the high pressure line to the power steering pump.
21. Connect the oil pressure switch plug connector.
22.
NOTE: Install the clamp at a 45 degree angle to horizontal.
Install the oil separator.
23. Raise and support the vehicle. Refer to Section 100-02 for additional information.
24.
NOTE: Use a new gasket.
Connect the turbocharger oil supply and return lines.
25. Attach the catalytic converter to the appropriate bracket.
26. Lower the vehicle.
27. Remove the camshaft bearing cap nuts.
28. Install the oil catch can.
29. Connect the vacuum hose to the vacuum diaphragm block.
30. Install the air cleaner outlet pipe.
31. Install the air cleaner. Refer to Section 303-12 for additional information.
32. Install special tools.
Cars manufactured up to 04.2001.
33. Remove the front engine mount.
Cars manufactured since 04.2001.
34. Remove the front engine mount.
All cars
35. Connect the rear timing belt cover (engine shown removed for clarity).
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 in this section.
38. Fill the cooling system with coolant and bleed the system. Refer to Section 303-03 for additional information.
39. Add power steering fluid and bleed the system. Refer to Section 211-00 for additional information.
40. Install the battery tray and install the battery. Refer to Section 414-01 for additional information.
41. Replace engine oil and oil filter.
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