47.1. Cylinder head installation details 1. Rear timing belt cover; 2. Rubber plug; 3. Hairpin, 15 Nm; 4. Intake shaft hub with CMP sensor rotor; 5. Hub mounting bolts 4 and 6, 100 Nm; 6. Exhaust shaft hub with CMP sensor rotor; 7. Cover fastening bolt 1, 10 Nm, installed on threaded varnish; 8. Rocker arm axle; 9. Rocker arm bolt, subject to replacement; 10. Cover gasket 11; 11. Head cover 24; 12. PCV hose; 13. Filler plug; 14. Gasket; 15. Plug; 16. Special cover mounting bolt 11, 10 Nm; 17. Vacuum hose; 18. Bolt, 20 Nm; 19. Head mounting bolt 24, subject to replacement; 20. Washer; 21. Pump mounting bolt 22, 20 Nm; 22. Twin pump; 23. Pump gasket 22, subject to replacement; 24. Cylinder head; 25. Head gasket 24; 26. SMR sensor; 27. Sensor mounting bolt 26, 10 Nm, installed on threaded varnish
2. The installation details of the camshafts and valves are shown in the illustration.
47.2. Timing belt parts 1. Pipe bracket, 10 Nm; 2. Cover fastening bolt 26, 20 Nm; 3. Rocker arm axle; 4. Axle bolt 3, needs to be replaced; 5. Head mounting bolt 15, subject to replacement; 6. Bolt washer 5; 7. Split valve lock crackers; 8. Spring plate 9; 9. Valve spring; 10. Oil deflector cap; 11. Valve guide bushing; 12/13. Inlet/outlet side rocker arm with pressed-in hydraulic compensator; 14. Sealing rings, subject to replacement; 15. Cylinder head; 16/17. Inlet/outlet valves; 18. Sealing ring; 19.22. Rocker axis; 20,21. Bolt, 10 Nm; 23. Bearing insert; 24/25. Exhaust/intake camshaft; 26. Camshaft cover
Removal and installation camshafts
3. Bring the radiator frame to the service position (by analogy with Section 6).
4. Remove the upper engine cover from the retainers (see illustration 46.8).
5. Disconnect the vacuum line (3 in the illustration).
47.5. Vacuum pipe (3) and water hoses (1 and 2)
Note: Do not disconnect the water hoses.
6. Remove the bolts (1 in the illustration) and nuts (2). Unscrew the bolts (arrows), remove the EGR radiator and set it aside with the cooling system hoses connected.
47.6. Removing the EGR cooler
7. Remove the bolts and the EGR cooler bracket from the cylinder head. Remove the timing belt (see Section 46).
47.7. EGR radiator bracket fastener
8. Remove the camshaft stoppers No.3359 and unscrew the bolts securing their gears (see illustration 46.10). Remove the gear wheels.
9. Loosen the bolts (1 in the illustration) fastening the hubs of both camshafts by approximately two turns, using counter support No. T10051.
47.9. Unscrewing the hub bolt (using the example of the intake shaft)
10. Alternately apply puller No. T10052 to the hub of each camshaft and screw the bolts into the hub (arrows in the illustration). Remove the hub by holding the hex key of the puller and screwing in the bolt.
47.10. Removing the hub (using the example of the intake shaft)
11. Remove the bolts (2 and 4 in the illustration).
47.11. Timing Belt Rear Cover Fastening Bolts
Note: Do not remove bolts 1, 3 and 5.
12. Remove the PCV hose and vacuum hose from the cylinder head cover (arrows in the illustration). Loosen the cylinder head cover bolts in sequence from 11 to 1 and remove it.
47.12. Cylinder head cover fastener tightening sequence
13. Loosen the locknuts (2 in the illustration) adjusting bolts (1) on all unit injector units and unscrew the adjusting bolts so that the corresponding rocker arm is pressed against the unit injector pusher spring.
47.13. Unscrewing the adjusting bolts
14. Remove the bolts (1, 3 and 5 in the illustration). Loosen and remove bolts (2 and 4) in several stages. Remove the rocker shaft and dual pump.
47.14. Removing the rocker arm shaft
Note: To ensure that individual components remain secured to the shaft, do not remove the rocker arm shaft bolts; if necessary, mark the position of the bolts on the rocker arm.
15. Remove the pin (1 in the illustration) and remove the knurled nut (2). Disconnect the central connector of the pump-injectors and glow plugs.
47.15. Pump-injector connector
16. Disconnect the glow plug connectors (And in the illustration) and pump-injector modules (B). Unscrew the screws (arrows) on the fasteners and set the wiring harness as a set aside.
47.16. Glow plug and pump-injector connectors
17. Loosen the remaining 15 camshaft cover bolts evenly, moving from the edge inward (see illustration).
47.17. Support module fastening bolts
18. Turn the bolts SW15 of frame No. T10262 counterclockwise by hand until they stop. Install the frame on the camshaft cover as shown in the illustration and tighten the bolts SW10 with a torque of 10 Nm. Turn the release bolts SW15 by hand clockwise until they rest against the cylinder head bolts, then evenly turn the release bolts in the sequence indicated on the bolt heads until the camshaft covers are separated from the cylinder head. Remove the camshaft cover and camshafts.
47.18. Removing the camshaft cover
19. Remove any remaining sealant from the bearing module and cylinder head, clean the mounting surfaces from oil and grease. Make sure the crankshaft is in the TDC position.
20. Lubricate the camshaft grooves with engine oil and set the shafts in the TDC position (see illustration): on both shafts, the cams (1 and 2) of cylinder No.1, as well as the grooves (arrows) must be facing upwards.
47.20. Position of camshafts at TDC
21. Apply a 2mm thick bead of sealant to the clean mounting surface of the support module (arrows in the illustration).
47.21. Places of sealant application
22. Tighten the bolts evenly (1-20 see illustration 47.17), moving from the center to the edge. Bolts (1, 3, 5, 7 and 9) pull to a 90° angle.
23. Further installation is carried out in the reverse order of dismantling the components.