- drain the engine oil;
- disconnect the AGR wire from the AGR valve. To do this, disconnect the hose and unscrew the wire;
- unscrew the right exhaust manifold and remove the gasket;
- unscrew the front drive shaft support plate;
- disconnect the following connectors and remove the following wiring harnesses - three-phase current generator wire, the corresponding connector related to the AGR system, the plug of the electronic low pressure regulator, the plug from the temperature sensor on the coolant distribution pipe. Loosen the two screws and unscrew the wire shaft (two screws);
- hang the wire from the control unit from the holder and then disconnect. Disconnect the plug and unscrew the screws of the intake manifold control unit;
- disconnect all spark plug connectors according to the designation used from the corresponding spark plugs, remove the ignition coil together with the ignition cables and connectors. To do this, disconnect the ignition coil connector, disconnect the ground wire, remove the capacitor, unscrew the screws and take out the ignition coil;
- disconnect the low pressure hoses: one from the upper intake manifold, one from the electronic low pressure regulator, one from the fuel pressure regulator and two from the remaining hoses already disconnected;
Fig. 321. Detachable hoses and connectors: 1 — throttle position angle sensor connector; 2 — crankcase ventilation hose; 3 — idle air valve connector
- disconnect connector 1 (Fig. 321) of the throttle position angle sensor, hose 2 of the crankcase ventilation, connector 3 of the idle speed valve;
- unscrew the upper part of the intake manifold as described in the relevant section;
- disconnect the connector from the hydraulic switch, camshaft position sensor, crankshaft position sensor and release the wires from the fasteners;
- disconnect the injection system cable harness. To do this, disconnect the connectors, including the valve injector connector;
- remove the thermostat housing with the coolant hose;
- unscrew the coolant distribution pipe (two screws at the bottom), unscrew the left bracket for removing or installing the engine and remove the oil dipstick;
Fig. 322. Removing the liquid pump drive belt
- remove the liquid pump drive belt (Fig. 322);
- remove the hose and the crankshaft ventilation adjustment valve. To do this, unscrew the nut and remove the hose with the valve;
- remove the coolant connecting pipe;
- Loosen the screws of the liquid pump and then disconnect the hose connected to the oil radiator;
- hold the flywheel properly and unscrew the screws. Then you can remove the intermediate plate located behind it;
- remove the rear crankshaft sealing ring. Be careful not to damage the crankshaft;
- remove the generator and the hanging console;
- remove the oil filter, the left intake manifold and unscrew the oil radiator located behind it (release the nut in the middle, remove the oil radiator). Now you can unscrew the switch with hydraulic drive located on the left;
- remove the oil pan as described above (while taking into account the sequence of unscrewing and screwing the screws);
- unscrew the screws securing the wires and remove the fastening;
- unscrew one screw and remove the right bracket for removing and installing the engine;
- remove both cylinder head covers as described above. The same applies to removing the belt pulley on the camshaft (see section "Replacing the camshaft sealing ring"). Now you can remove the camshaft oil sealing ring;
Fig. 323. Fastening the camshaft seal ring support
- unscrew the two screws (Fig. 323) and remove the sealing ring support. Try not to damage the camshaft;
- unscrew the belt pulley of the hydraulic power steering pump (four screws) and then unscrew the pump together with the console;
- unscrew the crankshaft belt pulley together with the vibration damper. The crankshaft must be secured against turning. The screw cannot be reused. To remove the damper, you must have the appropriate puller;
- remove the sensor and wire holders;
Fig. 324. Sequence of unscrewing the screws on the timing gear cover
- unscrew the timing cover from the front of the engine. When doing this, you must follow a certain order for unscrewing the screws (Fig. 324). Remove the gaskets. Now you can carefully remove the sealing ring from the hole;
Fig. 325. Crankshaft position: 1 — pulse ring; 2 - disc spring
- install the crankshaft in the correct position for subsequent disassembly (Fig. 325);
- unscrew the right chain tensioner and the right camshaft drive chain guide. Then place the tensioner in a vice (with metal jaws), clamp the jaws and press the piston inward until the pin can be inserted into the clamp hole. Once released from the vice, the tensioner is fixed and cannot be disassembled into parts;
Fig. 326. Right camshaft drive chain routing diagram: 1 — guide bar screws; 2 — camshaft drive chain
- mark the front side of the drive gear of the right camshaft drive chain with a felt-tip pen, unscrew the screws 1 (Fig. 326) of the guide bar on the right side and remove the drive chain 2 together with the crankshaft drive gear;
Fig. 327. Sequence of unscrewing the screws to remove the camshaft bearing caps on the left cylinder head (A) and the right cylinder head (B)
- remove both camshafts of the right cylinder head. To do this, first release both bearing housing covers No.1 and No.5. Then unscrew all the other screws only after the specified covers have been removed. Then unscrew the screws of the remaining covers according to the sequence shown in Fig. 327. Now you can remove the camshafts, tappets and valve tappets;
- screw the screw into the front end of the crankshaft and turn it to the right until the woodruff key is positioned at 11 o'clock. Then remove the screw;
Fig. 328. Left camshaft drive chain routing diagram: 1 — guide bar screws; 2 — camshaft drive chain
- remove the left camshaft drive chain. Mark the front side of the drive gear with a felt-tip pen, remove the tensioner and unscrew the left guide bar. Unscrew screws 1 (Fig. 328) of the right chain guide bar and remove chain 2 together with the gear;
- remove the two camshafts of the left cylinder head. First, release both bearing caps No.1 and No.5. Then unscrew all the remaining screws after the indicated caps have been removed. Then release the remaining caps according to the sequence shown in Fig. 327, taking into account that this head has two additional bearings. Now you can remove the camshafts, tappets and valve tappets;
- remove the spark plugs from the left cylinder head;
Fig. 329. Sequence of unscrewing the cylinder head screws. Both heads are unscrewed in the same way
- unscrew the cylinder head screws (Fig. 329) and remove the head. Then remove the gaskets;
- remove the spark plugs from the right cylinder head;
- unscrew the cylinder head screws (see Fig. 329) and remove the head. Then remove the gaskets;
- unscrew the hydraulic steering console, remove the oil separator and remove the gasket;
- install the cylinder block on the surface of the heads and unscrew the oil pump inlet pipe from the rear of the crankcase. Then remove the metal sheet located behind it (fastened in the corners);
- unscrew the oil pump from the front wall of the engine. First loosen the two screws on the left, then both screws on the right;
- turn the crankshaft (screw the screw into the shaft) until all the pistons are located approximately in the middle of their stroke, and using a scraper, carefully scrape off the rings of oil carbon from the upper cylinder bores, without damaging them;
- unscrew the connecting rod bearing caps one by one. Then lightly tap the cap with a rubber hammer and remove the cap together with the bearing shell. Usually the caps and connecting rods are marked with numbers, be sure to make sure that these marks are visible. The cylinder number is applied respectively to the connecting rod and the bearing cap in opposite places. Small rubber elements should be placed on the freely lying pin screws of the connecting rod so as not to damage the cylinder mirrors when installing the pistons;
- remove the pistons with connecting rods from the rear side through the cylinders. The corresponding piston should be at TDC to facilitate removal. It is best to screw the bearing caps and liners into the corresponding connecting rods so that they are together. Remove all pistons in the above sequence;
Fig. 330. Sequence of unscrewing the screws of the lower part of the crankcase
- unscrew the lower part of the crankcase (Fig. 330). Screws 7–22 are flexible screws that should always be replaced. Lift the housing part. If necessary, help with a rubber hammer;
Fig. 331. Crankshaft bearing shells: 1 — conventional shells; 2 - insert with flange
- remove the lower main bearing shells. Three shells 1 (Fig. 331) are identical, and one shell 2 has a clamping flange to compensate for the axial clearance of the crankshaft. Each shell is properly marked (e.g. with a colored line) so that they can be installed in their original position;
- carefully remove the crankshaft from the bearings and place it in a clean place;
- remove the bearing shells located in the crankcase, mark them accordingly so as not to mix them up, and put them with the other shells. Remove the thrust pressure disk from the crankcase side.
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