Removing
1. Remove the brake booster vacuum hose at the vacuum pump on the side of the cylinder head.
2. Disconnect the coolant hose from the connector on the cylinder head above the thermostat housing.
3. Remove the thin coolant hose near the 1st cylinder (from the toothed belt) above the intake manifold.
4. Clean the pump and injector supply line connections with a cold cleaner and unscrew them. Close the holes with appropriate caps to prevent contamination.
Attention! Do not change the bending of the supply pipes.
5. Remove the fuel return hose from the 5 cylinder injector.
6. Remove glow plugs and injectors (see subsection 2.17.7.2 and subsection 2.17.7.5).
7. Remove both toothed belts.
Installation
1. Finishing the cylinder head of a diesel engine is not allowed.
2. When replacing the gasket, pay attention to the designation and install a new gasket of the same designation. Designation of the cylinder head gasket with holes and notches (arrow) also visible when the cylinder head is installed. Depending on the protrusion of the pistons, cylinder head gaskets of various thicknesses are installed.
3. Always replace the cylinder head gasket. In this case, the new gasket must have the same designation as the old one. Only after installing new pistons or engine parts can the new piston protrusion be measured and the new gasket thickness determined.
Attention! Always replace cylinder head bolts.
4. The cylinder head bolts on a diesel engine are tightened in the same way as on a gasoline engine. However, diesel cylinder head bolts are additionally tightened when the engine is warm.
5. Install glow plugs (see subsection 2.17.7.2).
6. Install nozzles (see subsection 2.17.7.5).
7. Clean the supply line connections with a cold cleaner. Tighten union nuts to 25 Nm.
8. Attach the fuel return hose to the injector of cylinder 5.
9. Install both timing belts (see subsection 2.5.2.1).
10. Push the brake booster vacuum hose onto the vacuum pump on the side of the cylinder head and secure with a clamp.
11. Fit a thin coolant hose close to the 1st cylinder above the intake manifold and secure with a clamp.
12. Push the coolant hose onto the connecting pipe on the cylinder head above the thermostat housing and secure with a clamp.
13. Check the start of injection pump supply (see subsection 2.17.7.6).
Attention! Tighten the cylinder head bolts on a warm engine.
14. Warm up the engine until the fan turns on.
15. Remove the cylinder head cover.
16. Tighten all cylinder head bolts in the prescribed manner (see fig. Cylinder Head Bolt Tightening Order) with a hard wrench without pre-release and in one step by 1/4 turn (90°).
Attention! Further tightening of the cylinder head bolts after 1000 km of run is unacceptable.
17. Install the cylinder head cover.
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