16.3.1. Removal
The cylinder head can be removed without removing the engine, it is only necessary to partially remove the timing belt. A magnetic pointer gauge should be available to determine the required cylinder head gasket thickness. When these conditions are met, all parts between the cylinder head and the body are removed. For more details see. chapter "Diesel engine with a working volume of 2.5 liters".
- Remove both timing belt covers from the front of the engine. Use a strong screwdriver to push out the spring clamp in the middle. Also remove the casing from the bottom side.
- Insert the locking rod into the engine crankcase at the location shown in Figure 246. The crankshaft must be set to the top dead center position.
- Prepare three M8x40 bolts. Insert one of the bolts into the camshaft toothed pulley at location (4) in Figure 247, and the other two bolts at locations (6) and (7) into the high-pressure fuel pump drive pulley. When the crankshaft is correctly positioned, the bolts should insert easily. This way the valve timing mechanism is blocked.
- Loosen the fastening of both bolts (2) and (3) securing the timing belt tensioner roller, insert a 3/8-inch square rod (from a set of wrench heads) into the square hole (1) of the fastening and press the tension roller outward until the toothed belt is released. Retighten bolt (2) in Fig. 247 to hold the tensioner in its new position.
Figure 247. Front view of the engine with details on removing the timing belt. 1. Square hole; 2. Timing belt tensioner bolt; 3. Timing belt tensioner bolt; 4. Inserted locking bolt; 5. Engine mount bolt; 6. Inserted locking bolt; 7. Inserted locking bolt
- Carefully remove the timing belt from the timing pulleys.
- Loosen the camshaft toothed pulley mounting bolt and pull the pulley together with the inserted bolt off the shaft.
- Unscrew the cylinder head cover.
- Disconnect the injection pipes.
- In several passes in the reverse order to that shown in Figure 248, loosen the cylinder head bolts; Before subsequent installation, measure the length of the bolts, as it is prohibited to install bolts whose length differs from the specified one.
Figure 248. Cylinder head bolt tightening sequence. Unscrewing the bolts is done in reverse order.
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- Because the cylinder head sits on the guide bushing, it can sometimes be difficult to separate the head. At the service station, two bent iron rods are used for this purpose, which are inserted into the head, as shown in Figure 249. Both rods are lifted, which causes the separation of the cylinder head. The head is then moved to the side to allow the camshaft to pass through the rear timing plate. Immediately check where the centering sleeve is located. If it remains in the cylinder head, the bushing should be removed and placed in the cylinder block before installation.
Figure 249. Using iron rods to separate the cylinder head. Removal shown with the engine removed.
- Clean the contact surfaces of the cylinder head and cylinder block with a suitable cleaning fluid. Never clean surfaces with a hard scraper or sandpaper. Grinding of the cylinder head surface is not permitted. If the camshaft still rotates easily, no work needs to be done on it.
After removing the cylinder head, remove all attachments and remove the valves in the usual manner, as described in the relevant section.