Withdrawal
Attention! The engine is removed without a gearbox.
1. Remove the fairing grille.
2. Disconnect the wire terminal «masses» (-) from the negative pole of the battery by first turning off the ignition.
3. Unscrew the bolts / remove the clamps 1-5 and remove the engine mudguard (see illustration).
6.3. Unscrew bolts/remove clamps 1-5 and remove the engine mudguard
4. Unscrew the fastening bolts (see arrows in illustration) and remove the mudguard bracket.
6.4. Unscrew the fastening bolts (see arrows) and remove the mudguard bracket
5. Remove the front bumper (see relevant chapter).
6. Remove clamp 1 and disconnect the intercooler pipe (see illustration).
6.6. Remove the clamp 1 and disconnect the intercooler pipe
7. Remove the cover 2 of the air filter, and then disconnect the air intake 1 (see illustration).
6.7. Remove the cover 2 of the air filter, and then disconnect the air intake 1
8. Remove the engine protective cover by removing the plugs and unscrewing the nuts (see arrows in illustration).
6.8. Remove the engine protective cover by removing the plugs and unscrewing the nuts (see arrows)
9. Remove the bolt (see arrow in illustration) and remove the coolant hose holder.
6.9. unscrew the bolt (see arrow) and remove the coolant hose holder
10. Disconnect the air duct 1 connecting the intercooler and the intake manifold.
6.10. Disconnect air duct 1 connecting intercooler and intake manifold
11. Set the upper cross member of the front end to the service position (see paragraphs 3.1-3.6).
12. Unscrew the radiator fan with a viscous coupling, holding its hub from turning with a second wrench (see illustration).
6.12. Unscrew the radiator fan with a viscous coupling, holding its hub from turning with the second wrench
13. Remove the protective cover of the power steering reservoir (see arrow in illustration).
6.13. Remove the protective cover of the power steering reservoir (see arrow)
14. Disconnect the plug (see arrow in illustration) air conditioning compressor solenoid valve.
6.14. Disconnect the plug (see arrow) air conditioner compressor solenoid valve
Attention! All work related to the air conditioner should be entrusted to a specialized workshop. Do not open the refrigerant circuit yourself - risk of frostbite!
15. Remove the bolts (see arrows in illustration) and remove the protective cover of the accessory drive ribbed belt.
6.15. Unscrew the bolts (see arrows) and remove the protective cover of the accessory drive ribbed belt
16. Remove the bolts (see arrows in illustration) and remove the turbocharger heat shield.
6.16. Unscrew the bolts (see arrows) and remove the turbocharger heat shield
17. Unscrew the mounting bolts (see arrows in illustration) and disconnect the intake pipe.
6.17. Unscrew the fastening bolts (see arrows) downpipe
18. Unscrew the mounting bolts (see arrows in illustration) and remove the downpipe along with the catalyst.
6.18. Unscrew the fastening bolts (see arrows) and remove the exhaust pipe along with the catalyst
19. Remove the bolts (see arrows in illustration) and remove the engine mount.
6.19. Unscrew the bolts (see arrows) and remove the engine mount
20. Remove the plug of the tension roller of the A/C compressor drive belt, then loosen the belt tension by loosening the bolt A and turning the roller eccentric with a torque wrench C, and carefully remove the A/C compressor drive belt B (see illustration).
6.20. Loosen bolt A, turn the roller eccentric with a torque wrench C and carefully remove the A/C compressor drive belt B
Attention! All work related to the air conditioner should be entrusted to a specialized workshop. Do not open the refrigerant circuit yourself - risk of frostbite!
21. Unscrew the bolts A and remove the air conditioning compressor without disconnecting the hoses from it (see illustration). Carefully secure the A/C compressor with wire to the body, do not kink or twist the A/C compressor hoses. When installing, make sure that the centering sleeves B fit correctly.
6.21. Unscrew bolts A and remove the air conditioning compressor without disconnecting the hoses from it. When installing, make sure that the centering sleeves B fit correctly
22. Squeeze the plunger of the auxiliary drive belt tensioner into the housing with a bent socket wrench, pushing it in the direction of the arrow shown in the illustration, and lock the plunger with stop 1.
6.22. Squeeze the plunger of the auxiliary drive belt tensioner into the housing with a bent socket wrench, pushing it in the direction of the arrow and lock the plunger with stop 1
23. Remove the accessory drive ribbed belt from the power steering pump, alternator and radiator fan.
24. Unscrew the mounting bolts (see arrows in illustration) ribbed belt pulley to the crankshaft, keeping the pulley from turning with a trunnion key, for example, key 3212.
6.24. Unscrew the fastening bolts (see arrows) ribbed belt pulley to the crankshaft, holding the pulley from turning with a trunnion key 3212
25. Remove bracket (see arrow in illustration) power steering pump and move the pump away from the place of work without disconnecting the hoses from it.
6.25. Remove bracket (see arrow) power steering pump
26. Disconnect hose 1, and then plug 2 of the mass air flow sensor and remove the air filter cover together with the air supply duct (see illustration).
6.26. Disconnect hose 1 and then plug 2 of the mass air flow sensor and remove the air filter cover together with the air supply duct
27. Remove the generator (see relevant chapter).
28. Release the starter wire 1 from the holders by cutting the plastic clamps (see arrows in illustration).
6.28. Release the starter wire 1 from the holders by cutting the plastic ties (see arrows)
29. Disconnect wire 2 «masses» (-) from engine mount bracket (see illustration 6.28).
30. Release the plugs 3 from the holders on the right and left engine mounts (see illustration 6.28).
31. Disconnect wires from a starter and remove a starter.
32. Unscrew the lower bolts securing the gearbox to the engine, marking them and their mounting position.
33. Unscrew the screw plug 2 and drain the coolant (see illustration).
6.33. Unscrew the screw plug 2 and drain the coolant
Attention! The cooling system may have an additional drain hole closed by a plug, or be without one. In this case, the coolant is drained through the coolant temperature sensor mounting hole.
34. Engines with an additional threaded plug for draining the coolant. Unscrew the plug from the coolant drain hole on the outlet pipe and drain the coolant.
35. Engines without an additional hole for draining the coolant. Remove bracket 1 that holds the coolant temperature sensor, remove the sensor and drain the coolant (see illustration 6.33).
36. Disconnect hose 1 from the oil cooler, and then remove the clamps 2 and 3 and disconnect the coolant circulation hoses (see illustration).
6.36. Disconnect hose 1 from the oil cooler, and then remove the clamps 2 and 3 and disconnect the coolant circulation hoses
37. Disconnect the hoses from the coolant tank by removing the clamps 2, unscrew the bolts 1 and remove the coolant tank, then disconnect the coolant level sensor plug (see illustration).
6.37. Disconnect the hoses from the coolant reservoir by removing the clamps 2, unscrew the bolts 1 and remove the coolant reservoir
38. Disconnect the plug (see arrow in illustration) injector needle travel sensor and release the sensor wire from the holder.
6.38. Disconnect the plug (see arrow) injector needle travel sensor and release the sensor wire from the holder
39. Disconnect the hose with the check valve from the vacuum pump (see arrow in illustration).
6.39. Disconnect the hose with check valve from the vacuum pump (see arrow)
40. Disconnect the supply and return fuel lines from the injection pump and move them away from the work site.
41. Disconnect the low pressure hose of the boost air pressure regulator and move it away from the work area.
42. Disconnect the supply and return hoses (see arrows in illustration) from the heater core.
6.42. Disconnect supply and return hoses (see arrows) from the heater core
43. Release the wiring harness from the holders on the gearbox.
44. Disconnect plugs 1-3, plug 4 of the injection pump, plug 5 of the coolant temperature sensor (see illustration).
6.44. Disconnect plugs 1-3, plug 4 of the injection pump, plug 5 of the coolant temperature sensor
45. Disconnect the glow plug power plugs and move the glow plug wires away from the work area.
46. Mark the position of the right and left engine mounts and unscrew their lower bolts A (see illustration).
6.46. Mark the position of the right and left engine mounts and unscrew their lower bolts A
47. Remove both gas-filled hood stops, secure the hood in a vertical position and unscrew the upper bolts securing the gearbox to the engine.
48. Fasten the cables or special cross member 2024A to the lugs, make sure that all wires and hoses are disconnected from the engine, carefully lift the engine and remove it from the engine compartment (see illustration).
6.48. Attach cables or a special cross member 2024A to the lugs to lift the engine
Installation
The engine is installed in the reverse order of removal.
49. The tightening torque of the generator mounting bolts to the engine is: M8 bolts - 25 Nm, M10 bolts - 40 Nm.
50. The tightening torque of the air conditioning compressor mounting bolts is 25 Nm.
51. The tightening torque of the bolts of the bracket for fastening the power steering pump and oil cooler to the engine is 25 Nm.
52. The tightening torque of the front engine mount bolts is 45 Nm.
53. The tightening torque of the bolts securing the exhaust manifold to the cylinder head, as well as the exhaust pipe to the turbocharger, is 25 Nm.
54. The tightening torque of the turbocharger heat shield mounting bolts is 10 Nm.
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