GENERAL INFORMATION, Precautions when working with electrical equipment.
Removing
1. Disconnect "negative" battery wire.
2. Remove the cylinder head gasket.
ENGINE TD6, REPAIR WORK, Cylinder head gasket.
3. Establish on the block of cylinders a lifting bracket and fix it with a bolt.
4. Put the lifting chain on the bracket and completely hang the engine.
5. Remove the oil pump.
ENGINE TD6, REPAIR WORKS, Oil pump.
6. Take out a forward epiploon of a cranked shaft.
ENGINE TD6, REPAIR WORKS, Replacing the front crankshaft oil seal.
7. Turn away 4 bolts of fastening of the pump of the hydraulic booster of a steering, take away the pump and fix it.
8. Turn away a bolt of fastening of the top idle pulley of a belt of a drive of hinged units and remove a pulley.
9. Turn away a nut of fastening of the wire going from the storage battery to the generator, and take a wire aside.
10. Disconnect the connector from the generator.
11. Turn away 2 bolts of fastening of the generator to an arm, fasten with an arm of an idle pulley and remove the generator.
12. Turn away a nut of fastening of a tensioner of a belt of a drive of hinged units and remove a tensioner.
13. Remove and discard the tensioner arm seal.
14. Turn away a collar and disconnect an air hose from an intermediate cooler of air.
CAUTION: To prevent contamination, install plugs on exposed connectors.
15. Turn away 3 bolts of fastening of the compressor of the central air, take away the compressor aside and fix it.
16. Turn away 6 bolts of fastening of an arm of the compressor of a central air and remove an arm.
17. Turn away 14 bolts, take away a cover from the block and remove it. With the bolts loosened, the accessory drive belt tensioner is released.
18. Remove the camshaft drive chain from the fuel pump sprocket.
19. Push the lower chain tensioner plunger fully into the tensioner housing to secure it with the LRT-12-172 pin.
20. Remove the 3 bolts and remove the timing chain tensioner.
21. Remove the top damper of a chain of a drive of the fuel pump.
22. Turn away a bolt and remove the bottom damper of a chain of a drive of the fuel pump. Dispose of the bolt.
23. While holding the fuel pump drive sprocket, unscrew its fastening nut.
24. Install the LRT-12-178/1 puller on the fuel pump sprocket and, tightening the central bolt of the puller, remove the sprocket.
25. Remove the LRT-12-178/1 puller from the sprocket.
26. Remove the sprockets and chains from the crankshaft and from the fuel pump.
27. Turn away a bolt and remove the oil nozzle intended for chain lubrication.
28. With a sharp blade, separate the gasket from the timing cover and remove it.
Installation
1. Wipe the timing cover and mating surface, pins and pin sockets.
2. Using a blade, separate and remove the water pump gasket, then install a new timing cover gasket.
3. Wipe the oil nozzle and the corresponding mating surface.
4. Install the oil nozzle in place and tighten the mounting bolt. Tightening torque 10 Nm.
5. Wipe the sprockets of the crankshaft, fuel pump and their installation sites.
6. Wipe the oil and fuel pump drive chains.
7. Lubricate chains and sprockets.
8. Put the oil and fuel pump drive chains on the crankshaft and fuel pump sprockets.
9. Put sprockets with chains on the crankshaft and on the fuel pump.
10. Install the fuel pump sprocket nut and tighten it. Tightening torque 65 Nm.
11. Wipe the dampers of the fuel pump drive chain.
12. Put on an adjusting finger the lower damper of a chain of a drive of the fuel pump and fix it with a new bolt. Tightening torque 24 Nm.
13. Establish the top damper of a chain of a drive of the fuel pump.
14. Wipe the timing chain tensioner and counter mating surface. Make sure the oil passage is clean.
15. Install the tensioner in place and tighten the mounting bolts. Tightening torque 10 Nm.
16. Push in the tensioner plunger to remove the LRT-12-172 pin and seat the plunger against the tensioner shoe.
17. Wipe the camshaft drive chain.
18. Lubricate the camshaft drive chain.
19. Install the camshaft drive chain to the fuel pump sprocket.
20. Wipe the timing cover.
21. Install the timing cover on the cylinder block.
22. To properly position the accessory drive belt tensioner, temporarily install the tensioner arm.
23. Tighten the timing cover bolts evenly and sequentially. Tightening torque 15 Nm.
24. Remove the accessory drive belt tensioner lever.
25. Install the seal on the belt tensioner arm bushing.
26. Install the tensioner lever in place and tighten the mounting bolts. Tightening torque 10 Nm.
27. Wipe the air conditioning compressor bracket and mating surface.
28. Install the compressor bracket in place and tighten the mounting bolts. Tightening torque 25 Nm.
29. Wipe the compressor and mating surface, dowel pins and pin sockets.
30. Install the compressor in place, put on the wire "masses" and tighten the mounting bolts. Tightening torque 25 Nm.
31. Wipe the intercooler air hose and mating seat.
32. Put a hose on a radiator of an intercooler of air and fix it with a collar.
33. Wipe the generator and mating surface.
34. Wipe the idler bracket and mating surface.
35. Install the generator and idler bracket, tighten the bolts. Tightening torque 45 Nm.
36. Connect the positive wire to the generator, screw on the nut and tighten it. Tightening torque 13 Nm.
37. Connect the connector to the generator.
38. Wipe the top idler of the accessory drive belt and mating mating surface.
39. Install the roller in place and tighten the mounting bolt. Tightening torque 25 Nm.
40. Wipe the power steering pump and mating surfaces.
41. Install the power steering pump on the bracket and screw in the mounting bolts. Tighten the M8 bolts to 25 Nm and the M6 bolts to 10 Nm.
42. Install the crankshaft front oil seal.
ENGINE TD6, REPAIR WORKS, Replacing the front crankshaft oil seal.
43. Install the oil pump.
ENGINE TD6, REPAIR WORKS, Oil pump.
44. Unhook the rigging chains.
45. Turn away a bolt of fastening of a lifting eye and remove an eye.
46. Install the cylinder head gasket.
ENGINE TD6, REPAIR WORK, Cylinder head gasket.
47. Attach "negative" wire to the battery.
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