GENERAL INFORMATION, Precautions when working with electrical equipment.
Removing
1. Place the car on a lift.
2. Disconnect "negative" battery wire.
3. Remove the battery cover, unscrew the nut and remove the positive terminal from the battery.
4. Remove the air receiver.
HEATING AND VENTILATION, REPAIR WORKS, Air intake box.
5. Remove the lower protective cover.
EXTERIOR PARTS, REPAIR WORKS, Engine protection - front.
6. Drain the engine coolant.
COOLING SYSTEM: Td6, ADJUSTMENTS AND MAINTENANCE, Coolant drain, system flush and fill.
7. Drain the engine oil.
MAINTENANCE, SERVICE OPERATIONS, Engine oil and oil filter - Td6 engine.
8. Remove the exhaust system.
EXHAUST MANIFOLD AND EXHAUST GAS SYSTEM: Td6 engine, REPAIR WORK, Exhaust system and system components suspension.
9. Remove the front propeller shaft.
DRIVE SHAFTS, REPAIR WORKS, Cardan shaft - front.
10. Remove the O-ring from the support bearing housing of the right wheel drive shaft.
DRIVE SHAFTS, REPAIR WORKS, O-ring - differential cover with drive shaft bearing support.
11. Remove the differential seal.
FRONT AXLE MAIN GEAR AND DIFFERENTIAL, Final drive with differential assembly - Td6, Seal - differential output shaft.
12. Remove the soundproof casing from the engine.
ENGINE TD6, REPAIR WORKS, Soundproofing engine cover.
13. Remove the air filter.
ENGINE MANAGEMENT Td6:, REPAIR WORK, Air cleaner element.
14. Remove the accessory drive belt.
SYSTEM OF STARTING THE ENGINE AND CHARGING THE BATTERY, REPAIR WORKS, Attachment drive belt - Td6 engine.
15. Remove the starter.
SYSTEM OF STARTING THE ENGINE AND CHARGING THE BATTERY, REPAIR WORKS, Starter - engine Td6.
16. Loosen the clamp and disconnect the air hose leading to the intercooler from the EGR valve. Dispose of the clamp.
CAUTION: To prevent contamination, install plugs on exposed connectors.
17. Turn away a collar and disconnect an air hose from an intermediate cooler of air. Take out the air hose.
18. Turn away a collar and disconnect an air hose from a turbocharger. Dispose of the clamp.
CAUTION: To prevent contamination, install plugs on exposed connectors.
19. Disconnect the vacuum hose from the turbocharger bypass valve.
CAUTION: To prevent contamination, install plugs on exposed connectors.
20. Remove a collar, disconnect an air hose of a turbocharger from an intercooler of air and take out a hose.
21. Disconnect the vacuum hose from the vacuum reservoir.
CAUTION: To prevent contamination, install plugs on exposed connectors.
22. Release vacuum hoses from supporting collars.
23. Turn away 3 bolts of fastening of the compressor of the central air, take away the compressor aside and fix it.
24. Turn away 4 bolts of fastening of the pump of the hydraulic booster of a steering, take away the pump and fix it.
25. Turn away a collar and disconnect the top hose of a radiator from an output branch pipe of system of cooling.
26. Turn away a collar and disconnect the bottom hose of a radiator from the thermostat case.
27. Turn away a collar and disconnect a hose of system of cooling from the heat exchanger of system recirculation of the fulfilled gases.
28. Turn away a collar and disconnect a hose of a broad tank from the pipeline of system of cooling.
29. Turn away a collar and disconnect a heater hose from a tube of system of cooling.
30. Loosen the clamp and disconnect the hose from the heater radiator valve.
31. Loosen the nut securing the transmission oil cooling system hoses to the engine sump.
32. Turn away 3 bolts of fastening of the heat exchanger of cooling of transmission oil, take the heat exchanger aside and fix it.
33. Release the vacuum hose on the left engine mount from the three clamps.
34. Disconnect the vacuum pump hose from the tee.
CAUTION: To prevent contamination, install plugs on exposed connectors.
35. Disconnect the connector from the fuel pressure sensor.
36. Disconnect the connector from the fuel temperature sensor.
37. Release the fuel pressure and temperature sensor harnesses from the support clamp.
38. Loosen the clamp and disconnect the fuel hose from the fuel filter, and the fuel flow regulator hose from the tee.
ATTENTION: Before disconnecting or removing engine components, the places immediately adjacent to the mating surfaces or connectors must be cleaned of dirt. To prevent contamination, place plugs on open connectors.
39. Loosen the clamp and disconnect the fuel return hose from the fuel flow regulator.
40. Remove the hose from the differential breather.
CAUTION: To prevent contamination, install plugs on exposed connectors.
41. Release the gearbox breather hoses from the supporting clamps and take them aside.
42. Turn away a collar and disconnect a vacuum hose of brake system.
CAUTION: To prevent contamination, install plugs on exposed connectors.
43. Remove the 10 mounting box cover bolts and remove the cover.
44. Remove the wire fastening nut "masses" to the body and remove the wire from the stud.
45. Disconnect the connector from the EGR solenoid valve.
46. Disconnect 5 connectors from the engine control unit.
47. Disconnect 2 connectors from the transmission control unit.
48. Disconnect the support of the glow plug control unit from the mounting box and disconnect the connector.
49. Disconnect "positive" the wire.
50. Remove the fuse and relay box from the junction box.
51. Disconnect the connector.
52. Remove the wiring harness seals from the junction box.
53. Turning, disconnect the connector from the gearbox.
54. Release the transmission harness from the support clamps.
55. Remove the plug from the drive plate crankcase hatch to gain access to the torque converter mounting bolts.
56. Using the LRT-12-212 tool, rotate the crankshaft and unscrew the 3 bolts securing the drive disc to the torque converter one by one.
57. Turn away a bolt of fastening of a hatch to a transmission.
58. Disconnect the connector from the boost pressure sensor.
59. Turn away a bolt of fastening of the gauge of pressure of boost and remove the gauge. Dispose of the gasket.
CAUTION: To prevent contamination, install plugs on exposed connectors.
60. Install the hooks LRT-12-216 on the lifting chains and hook them onto the lifting eyes of the engine.
61. Turn away 2 nuts of fastening of basic arms of the engine to supports.
62. Raise the engine so that it is completely off the supports.
63. Establish a supporting rack under a transmission.
64. Turn away 4 bolts of fastening of a transmission to the pallet of the engine and remove a plate.
65. Turn away 4 bolts of fastening of a transmission to the engine.
66. Release the engine from the guide pins, carefully lift it and take it away from the car.
CAUTION: Make sure the torque converter remains on the gearbox.
67. Remove the hatch.
Installation
1. Wipe down the torque converter and mating surfaces.
2. Make sure the torque converter is fully engaged with the transmission.
3. Wipe the mating surfaces of the engine and gearbox, dowel pins and pin sockets.
4. Wipe the hatch.
5. Install the hatch on the pins.
6. Using the help of a partner, carefully connect the engine to the gearbox. Make sure that the torque converter centering bushing fits accurately and that the pins fit into the sockets.
7. Screw in bolts of fastening of a transmission to the engine and tighten them. Tightening torque 45 Nm.
8. Remove the hydraulic strut from under the gearbox.
9. Lower the engine onto stands.
10. Remove lifting chains from the engine.
11. Screw and tighten the nuts securing the engine support brackets to the supports. Tightening torque 100 Nm.
12. Install the plate on the gearbox flange and tighten the bolts securing the gearbox to the engine pan. Tightening torque 22 Nm.
13. Screw in a hatch fastening bolt and tighten it. Tightening torque 10 Nm.
14. Screw in bolts of fastening of a leading disk to the hydrotransformer and tighten them. Tightening torque 45 Nm.
15. Install the plug on the hatch.
16. Attach the connector to the gearbox and secure the wire harness in the clamps.
17. Pull the motor harness to the junction box, attach the connectors and positive wire. Connect the connector to the glow plug control unit.
18. Install the fuse block, relay in the mounting box and fix the glow plug control unit on it.
19. Connect the connectors to the engine and transmission control units.
20. Put on the wire "masses" on the stud, screw on the nut and tighten it. Tightening torque 25 Nm.
21. Install the wire harness glands on the junction box.
22. Replace the junction box cover and tighten it with bolts. Tightening torque 2 Nm.
23. Attach a vacuum hose of brake system and fix it with a collar.
24. Install the starter.
SYSTEM OF STARTING THE ENGINE AND CHARGING THE BATTERY, REPAIR WORKS, Starter - engine Td6.
25. Clean the fuel hose connectors.
26. Connect the fuel return hose to the fuel flow regulator.
27. Connect the hose to the fuel filter and the fuel flow regulator hose to the tee.
28. Connect the connector to the fuel temperature sensor.
29. Connect the connector to the fuel pressure sensor.
30. Fasten the wire harness in the clamps.
31. Attach the vacuum supply hose and secure it in the clamps.
32. Wipe the transmission oil cooling heat exchanger and mating surface.
33. Reinstall the engine oil cooling heat exchanger and tighten its mounting bolts.
34. Tightening torque 10 Nm. Tighten the transmission oil cooler hose nut.
35. Put the hose on the differential breather and secure it in the clamp.
36. Secure the gearbox breather hoses in the clamps.
37. Wipe the boost pressure sensor and its installation site.
38. Place a new gasket on the sensor and secure it with a bolt to the intake manifold. Tightening torque 8 Nm.
39. Attach the heater hose to the cooling system pipe and secure it with a clamp.
40. Connect the hose to the heater tap and tighten the clamp.
41. Attach the expansion tank hose to the cooling system pipe and secure it with a clamp.
42. Attach the upper radiator hose and secure it with a clamp.
43. Attach the lower radiator hose and secure it with a clamp.
44. Connect the cooling system hose to the EGR system heat exchanger and tighten the clamp.
45. Wipe the power steering pump and mating surfaces.
46. 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.
47. Wipe the air conditioning compressor bracket and mating surface.
48. Install the compressor in place, put on the wire "masses" and tighten the mounting bolts. Tightening torque 25 Nm.
49. Connect the vacuum hose to the turbocharger bypass valve.
50. Connect the vacuum hose to the vacuum reservoir.
51. Fix a vacuum hose in collars.
52. Wipe a branch pipe of a turbocharger and a mating part of an air hose.
53. Install the hose connecting the turbocharger to the intercooler. Use a new clamp. Tighten the clamp to 6 Nm.
54. After waiting 15 minutes, re-tighten the clamp securing the air hose to the turbocharger. Tightening torque 6 Nm.
55. Wipe the pipe on the EGR valve and the counterpart of the intake hose.
56. Using a new clamp, secure the air hose from the intercooler to the EGR valve. Clamp tightening torque 6 Nm.
57. After waiting 10 minutes, tighten the air hose clamp to the valve again. Tightening torque 6 Nm.
58. Install the accessory drive belt.
SYSTEM OF STARTING THE ENGINE AND CHARGING THE BATTERY, REPAIR WORKS, Attachment drive belt - Td6 engine.
59. Install the air filter.
ENGINE MANAGEMENT Td6:, REPAIR WORK, Air cleaner element.
60. Install the engine soundproof cover.
ENGINE TD6, REPAIR WORKS, Soundproofing engine cover.
61. Install the differential seal.
FRONT AXLE MAIN GEAR AND DIFFERENTIAL, Final drive with differential assembly - Td6, Seal - differential output shaft.
62. Install the right wheel drive shaft thrust bearing housing O-ring.
DRIVE SHAFTS, REPAIR WORKS, O-ring - differential cover with drive shaft bearing support.
63. Install the front driveshaft.
DRIVE SHAFTS, REPAIR WORKS, Cardan shaft - front.
64. Install the exhaust system.
EXHAUST MANIFOLD AND EXHAUST GAS SYSTEM: Td6 engine, REPAIR WORK, Exhaust system and system components suspension.
65. Fill the engine with oil.
MAINTENANCE, SERVICE OPERATIONS, Engine oil and oil filter - Td6 engine.
66. Install the lower casing.
EXTERIOR PARTS, REPAIR WORKS, Engine protection - front.
67. Install the intake air receiver.
HEATING AND VENTILATION, REPAIR WORKS, Air intake box.
68. Put the battery positive cable terminal on the pole piece, tighten the nut to 18 Nm and put on the cover.
69. Attach "negative" wire to the battery.
70. Fill the engine with coolant.
COOLING SYSTEM: Td6, ADJUSTMENTS AND MAINTENANCE, Coolant drain, system flush and fill.
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