Note. After turning off the ignition, wait 15 minutes before disconnecting the battery (to ensure results are remembered «learning» various computers).
Disconnect the battery.
Remove the implement drive belt.
Remove:
- timing belt;
- fuel filter;
- diesel fuel filter support;
- exhaust gas recirculation solenoid valve;
- nozzles;
- integrated air intake system;
- catalytic converter.
Recommended fixtures:
1 - head for cylinder head bolt 0185;
2 - auxiliary levers for separating the head from the cylinder block 0188-L;
3 - indicator 1504;
4 - support of the pointer indicator 0110;
5 - tool for setting the correct position of the camshaft 0194-N.
Remove the turbocharger and alternator.
Remove the dynamic tensioner roller (3), unscrew the bolts (2) and remove the multifunction support (1).
Remove:
- Vacuum pump;
- coolant outlet block;
- mounting bolts and valve cover;
- sealing ring.
Loosen the nut (5).
Remove the top stud (4) high pressure fuel pump with two nuts or a FACOM puller.
Remove the brackets with their lock (observe the position of each element).
Remove the cylinder head bolts using the tool [1] (in that order). Remove the cylinder head using tool [2].
Flatness check
Check the flatness of the cylinder head (according to the scheme).
Maximum allowable deformation: 0.05 mm.
Checking the height of the valves
Check the protrusion of the valves in relation to the plane of the cylinder head (control points «A»):
- Exhaust valve «A» - 0.85 mm;
- inlet valve «IN» - 0.7 mm.
Note. Calculate the average value based on the four results obtained (see tables «Data for adjusting and monitoring the mechanical part of petrol and diesel engines»).
Checking cylinder head bolts before reusing them
Measure the length of reusable bolts: size «WITH» must be less than 149 mm.
Checking cylinder head bolts before reusing them
Measure the length of reusable bolts: size «WITH» must be less than 149 mm.
Head gasket selection
Choose the right gasket (see tables «Data for adjusting and monitoring the mechanical part of petrol and diesel engines»).
Fit the tools [3], [4]. Remove the crankshaft lock pin.
Install the end of the indicator rod on the top plane of the cylinder block.
Set the dial gauge to zero.
Set the end of the indicator to one of the control points (check Point «With»).
Rotate the crankshaft clockwise until the piston reaches top dead center without going beyond it.
Read the resulting value.
Set the end of the indicator to one of the control points (check Point «b»).
Read the resulting value.
Calculate the average value based on the two results.
Do the same for the other cylinders.
Note. Maximum difference between two pistons: 0.1 mm.
Pass a tap a carving of openings of fastening of a head of cylinders. Clear a plane of a prileganiye of a laying of the block.
Lock the flywheel.
Make sure you have pins (in the zone «d»).
Install a new cylinder head gasket having a predetermined thickness (observing the correct installation direction) . Install the block head.
Clean the threads of the cylinder head bolts with a brush.
Reinstall the cylinder head bolts, pre-applying grease «MOLYKOTE G RAPID PLUS» on threads and under bolt heads.
Tighten the cylinder head bolts in sequence (using fixture 1).
Clean the connecting plane with a solvent «DECAPLOC — DECAPJOINT».
Note. Do not use abrasive or piercing attachments or tools.
Apply a thin layer of sealing paste around the perimeter of the plane to be joined.
Attention. Protect the oil passages of the hydraulic timing chain tensioner from sealing paste (in the zone «e»).
Retaining clips are provided to hold the stoppers when installing the crankcase of the shaft support covers. Install a latch in the zone «f» between rockers (7) and hydraulic pushers (b), to hold them in place while installing the cylinder head cover.
Make sure the pushrods rotate freely in the cylinder head.
Install the roller rocker retainer on the pushrods.
Install the valve actuation levers together with their hydraulic tappets, respecting their original position.
Note. Before installing the valve cover, check the correct operation of the roller rocker arms on the valve lifters.
Replace the tools [5].
Install the valve cover to the cylinder head.
Tighten, and then alternately tighten the mounting bolts in the prescribed order (see table «Tightening torques for the mechanical part of gasoline and diesel engines»).
Install the parts in reverse order.