GENERAL INFORMATION, Precautions when working with electrical equipment.
Removing
1. Disconnect "negative" battery wire.
2. Drain the coolant from the cooling system.
COOLING SYSTEM: Td6, ADJUSTMENTS AND MAINTENANCE, Coolant drain, system flush and fill.
3. Remove the heat exchanger of system recirculation of the fulfilled gases.
EMISSION REDUCTION SYSTEMS - Td6, REPAIRS, EGR cooler (EGR).
4. Remove hydraulic lifters.
ENGINE TD6, REPAIR WORKS, Hydraulic compensators.
5. Disconnect the connector from the fuel pressure sensor.
6. Disconnect connectors from glow plugs.
7. Disconnect the connector from the coolant temperature sensor.
8. Turn away three bolts and take away a branch pipe of system of cooling from a head of cylinders. Dispose of the gasket.
9. Having loosened nuts, disconnect fuel tubes from a fuel stage and the fuel pump. Assemble the fuel pipe support bushings.
CAUTION: To prevent contamination, install plugs on exposed connectors.
10. Turn away 3 bolts and remove a fuel stage.
11. Turn away 2 bolts of fastening of a heat-shielding screen and tubes of system EGR to a final collector.
12. Remove the heat shield.
13. Remove the tube of the EGR system with a clamp.
14. Turn away two bolts of fastening of a lifting eye and remove an eye.
15. Turn away a collar and disconnect a hose of a broad tank from a water tube.
16. Turn away 2 bolts of fastening of a water tube.
17. Turn away a collar, disconnect a water tube from the thermostat case and take it aside.
18. Turn away 3 bolts of fastening of a turbocharger to a final collector. Dispose of the gasket.
19. Turn away a bolt of fastening of a supporting collar of a vacuum hose and a wire plait to a head of cylinders.
20. Remove the camshaft drive chain from the sprockets.
21. Remove and discard the timing chain damper clips.
22. Remove the chain guides. Access to the guide from the intake side will be better with the cylinder head removed.
23. Turn away 7 bolts of fastening of a head of cylinders to a cover of the gas distribution mechanism.
24. In the specified sequence, unscrew and dispose of the 14 cylinder head bolts.
25. Establish on a head of cylinders and fix on it rigging eyes.
26. Attach lifting chains to the lifting eyes, lift the head from the guide pins and remove it from the engine. Care must be taken not to damage the protruding glow plugs.
27. By the number of notches in the gasket, determine its thickness. Remove and discard gasket.
Installation
1. Clean the surfaces of the block head, cylinder block, pins and pin holes. If necessary, remove residual sealant with a hardwood scraper. Make sure that no residue of the removed sealant gets into the oil and water channels and threaded sockets.
2. Using a straightedge and a feeler gauge, check the deformation of the bottom plane of the head in the directions shown in the figure.
3. If the curvature of the lower plane exceeds the maximum allowable, then the cylinder head must be replaced. Milling of the lower plane of the head is not allowed.
4. The new gasket must have the same thickness (number of notches) as before, unless new pistons and connecting rods were installed. If new pistons and connecting rods were installed, then to select a new gasket for thickness, it is necessary to measure the protrusion of the pistons.
5. After making sure that the sealant strips on the gasket are not damaged, install the gasket on the cylinder block.
6. Lightly lubricate the new cylinder head bolts with engine oil.
7. Carefully place the cylinder head on the block so that the pins fit into the sockets.
8. Insert new bolts of fastening of a head and tighten them in the specified sequence the moment of 80 Нм. Loosen all bolts half a turn and retighten them. Tightening torque 50 Nm. Using an angle torque wrench, tighten all bolts in the sequence shown by 90°and again by 90°.
9. Tighten bolts of fastening of a head of cylinders to a cover of the gas distribution mechanism. Tightening torque 20 Nm.
10. Wipe the dampers of the gas distribution chain.
11. Replace the chain guides so that the intake guide is on the lower clip and tighten both new upper clips. Tightening torque 20 Nm.
12. Wipe the camshaft sprockets.
13. Put the camshaft drive chain on the sprockets.
14. Wipe the turbocharger and mating surface on the exhaust manifold.
15. Install the turbocharger on a new gasket and tighten the bolts of its fastening. Tightening torque 50 Nm.
16. Install the vacuum hose and wire harness support clamps, tighten the bolt. Tightening torque 10 Nm.
17. Wipe the tubes of the engine cooling system and mating surfaces.
18. Attach the tube of the engine cooling system to the thermostat housing and secure it with a clamp.
19. Screw in bolts of fastening of a tube of system of cooling of the engine and tighten them. Tightening torque 10 Nm.
20. Attach a hose to a broad tank and fix it with a collar.
21. Replace the lifting eye and tighten the bolts. Tightening torque 25 Nm.
22. Wipe the tube of the exhaust gas recirculation system and mating surface.
23. Install the EGR pipe, heat shield, Torx bolts, but do not tighten yet. The bolts are tightened after installing the EGR heat exchanger. Tightening torque 25 Nm.
24. Wipe the coolant pipe and mating seat.
25. Put a branch pipe of the cooling system on a new gasket and tighten the bolts. Tightening torque 8 Nm.
26. Install the fuel rail in place and tighten the mounting bolts. Tightening torque 24 Nm.
27. Install the high pressure fuel pipes and support sleeve, tighten the nuts on the pipes. Tightening torque 20 Nm.
28. Connect the connector to the coolant temperature sensor.
29. Put the connectors on the glow plugs.
30. Connect the connector to the fuel pressure sensor.
31. Reinstall pushers.
ENGINE TD6, REPAIR WORKS, Hydraulic compensators.
32. Install the exhaust gas recirculation heat exchanger.
EMISSION REDUCTION SYSTEMS - Td6, REPAIRS, EGR cooler (EGR).
33. Attach "negative" wire to the battery.
34. Fill the engine with coolant.
COOLING SYSTEM: Td6, ADJUSTMENTS AND MAINTENANCE, Coolant drain, system flush and fill.
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