Remove the toothed belt.
Cars with air conditioning. After removing the front bumper, unscrew the bolt securing the air conditioning pipe (see fig. 2.63). Do not disconnect the air conditioning pipes.
Unscrew and remove the exhaust manifold and turbocharger heat shield.
Unscrew the EGR valve from the cylinder head (see fig. 2.64).
Unscrew the bolts and remove the front section of the intake manifold (see fig. 2.65).
Unscrew the supply and return pipes. Plug open pipes.
Clean the piping connections to the fuel injectors and high pressure fuel pump. Unscrew the connecting nuts and remove the fuel lines. Close the holes with suitable plugs.
Unscrew the fuel pump mounting bolts and remove the pump together with the pipelines connected to it (see fig. 2.66).
Unscrew the screws and remove the toothed belt covers (see fig. 2.67).
Loosen the clamps, unscrew the two bolts and remove the front pipe of the cooling system (see fig. 2.68).
Unscrew in sequence from 8 to 1 bolts of fastening of a head of the block of cylinders (see fig. 2.70).
Remove the cylinder head and lay it on a soft base, otherwise the injectors and glow plugs will be damaged.
If new pistons are installed on the engine, the protrusion of the pistons from the cylinder block must be measured and, based on the protrusion of the pistons, the thickness of the new cylinder head gasket must be selected (see fig. 2.69).
Install the gasket on the guide pins, while the inscription "oben" should point towards the head.
Install the cylinder head. Insert the cylinder head bolts and tighten by hand.
In the sequence shown in Figure 2.70, tighten the cylinder head mounting bolts in four stages.
Step 1 - Tighten to 35 Nm.
Step 2 - Tighten to 60 Nm.
Step 3 - Tighten 90°.
Step 4 - Tighten 90°.
Remove air from the fuel system.
Install the toothed belt.
Check the fuel injection timing.
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