Remove the timing belt.
Cars with air conditioning. After removing the front bumper, unscrew the bolt securing the air conditioning system pipe (see fig. 2.63). Do not disconnect the air conditioning system pipes.
Unscrew and remove the exhaust manifold and turbocharger heat shield.
Unscrew the exhaust gas recirculation valve from the cylinder head (see fig. 2.64).
Remove the bolts and the front section of the intake manifold (see fig. 2.65).
Unscrew the supply and return pipes. Close the open pipes with plugs.
Clean the connection points of the pipes to the fuel injectors and the high-pressure fuel pump. Unscrew the union nuts and remove the fuel pipes. Close the holes with suitable plugs.
Unscrew the fuel pump mounting bolts and remove the pump together with the pipes connected to it (see fig. 2.66).
Unscrew the screws and remove the timing belt covers (see fig. 2.67).
Loosen the clamps, unscrew the two bolts and remove the front coolant pipe (see fig. 2.68).
Unscrew the cylinder head mounting bolts in sequence from 8 to 1 (see fig. 2.70).
Remove the cylinder head and place it on a soft surface, otherwise the injectors and glow plugs will be damaged.
If new pistons are installed on the engine, it is necessary to measure the piston protrusion from the cylinder block and, based on the amount of piston protrusion, it is necessary to select the thickness of the new cylinder head gasket (see fig. 2.69).
Place the gasket on the guide pins with the "oben" lettering facing the head.
Install the cylinder head. Insert the cylinder head mounting bolts and tighten them by hand.
Tighten the cylinder head mounting bolts in four stages in the sequence shown in Figure 2.70.
Step 1 - tighten to 35 Nm.
Step 2 – tighten to 60 Nm.
Step 3 - turn to an angle of 90°.
Step 4 - turn to an angle of 90°.
Remove air from the fuel system.
Install the timing belt.
Check the fuel injection timing.
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