Table of contents: Removal ↓ Installation ↓
Removal
Remove the front cross member.
Fig. 3.4–19. Removing the engine casing
Remove the engine cover by pulling it upwards by the sides (see Fig. 3.4–19).
Loosen the screws and remove the protective cover located behind the air filter.
Fig. 3.4–1. Location of clamps (1) for fastening the air pipe and screws for fastening the air filter
Loosen the clamps and remove the air duct connecting the air filter and the air pipe (see Fig. 3.4–1).
Loosen the air filter housing mounting screws.
Fig. 3.4–2. Location of air pipe mounting screws
Loosen the screws and remove the air pipe (see Fig. 3.4–2).
Fig. 3.4–48. Location of the connecting nut (1) and bolts (2, 3) of the fuel injection unit
Unscrew the end union nut 1 (Fig. 3.4–48).
Unscrew bolts 2 and 3, but do not remove the injection unit completely.
Fig. 3.4–49. Location of electrical connectors, bolts and connecting nuts for fastening fuel lines to the injection control unit (Rail element): 1, 3 – electrical connectors; 2, 4 – bolts; 5, 6, 7, 8 – connecting nuts
Disconnect electrical connectors 1 and 3 (Fig. 3.4–49), unscrew connecting nuts 5–8 securing the pipelines and bolts 2 and 4 securing the fuel injection control unit (Rail element).
Disconnect the electrical connectors from the glow plugs.
Remove the injection control unit (Rail element) from the intake manifold.
Fig. 3.4–50. Location of the fuel return line (1) and electrical connectors (2–7).
Disconnect electrical connectors 2–7 (Fig. 3.4–50).
Unscrew the wire fastening clamp and move the wires to the side (see Fig. 3.4–50).
Release the return fuel line 1 from the clamps and remove it from the fuel injectors.
Fig. 3.4–51. Location of the clamp (1) for fastening the fuel hose to the T-shaped branch and fastening the fuel line (2) to the fuel supply pump
Loosen clamp 1 and remove the fuel hose from the T-piece (Fig. 3.4–51).
Remove the spring clip and disconnect the fuel line from the fuel supply pump (see Fig. 3.4–51).
Disconnect the fuel lines near the right cylinder head cover.
Unscrew the oil filler cap.
Fig. 3.4–43. Location of the notch in the oil filler neck opening
Using the crankshaft pulley mounting bolt, turn the shaft until a recess is visible in the oil filler neck hole (see Fig. 3.4–43).
Fig. 3.4–44. Location of fuel injector housing mounting bolts
Loosen the injector housing mounting bolts, pull the housings upwards and turn them 90° counterclockwise (see Fig. 3.4–44).
Fig. 3.4–45. Location of fuel injector mounting bolts
Unscrew the exposed injector mounting bolts (see Fig. 3.4–45).
Pull up and remove the injectors for cylinders 1 and 3. You can use a lever to remove the injectors.
Turn the crankshaft clockwise 180° and remove the injectors of cylinders 2 and 4.
Fig. 3.4–46. Location of cylinder head cover mounting bolts
Unscrew the bolts and remove the right cylinder head cover (see Fig. 3.4–46).
Installation
Installation is carried out in the reverse order of removal, taking into account the following.
Replace the fuel return line seals.
Replace the cylinder head cover gasket if necessary.
Install the sealing half ring.
Degrease the surface where the cylinder head cover gasket will be installed.
Fig. 3.4–47. Places to apply sealant before installing the left cylinder head cover
Apply a thin, continuous layer of sealant to the semicircular surface (see Fig. 3.4–47) at the end of the cylinder head.
Apply a 3 mm diameter layer of sealant to the outer camshaft covers in 5 mm long sections (see Fig. 3.4–47).
Tighten the cylinder head cover nuts gradually in a crosswise pattern.
Install the front cross member.
Fill the cooling system with coolant.