Special tool
Injection timing rod - automatic transmission 303-1117 | Injection timing rod - manual transmission 303-1116 | Device for fixing the camshaft pulley 303-1145/1 |
Holder - front camshaft pulley 303-1124 | Tool for locking faceplate 303-947 | Flywheel locking device 303-1123 |
Disassembly
1. Disconnect a wire of weight from the accumulator. For more information, refer to Specification
2.
WARNING: It is forbidden to carry out work on a vehicle supported only by a jack. Always place the vehicle on secure stands.
Raise and support the vehicle.
3. Drain the engine oil. For more information, refer to Draining and Refilling Engine Oil (12.60.05)
4. Remove the engine. For more information, refer to Engine - The vehicle is equipped with: Automatic transmission (12.41.01.99) For more information, refer to Engine - Vehicle is equipped with: Manual transmission (12.41.01.99).
5. Mount the engine on a suitable engine stand.
6. Remove the power steering pump bracket. Turn out 3 bolts.
7. Remove the air conditioning compressor.
- Disconnect the electrical connector.
- Turn out 3 bolts.
8. Remove the A/C compressor bracket. Turn out 2 bolts.
9. Remove the left engine support bracket. Turn out 4 bolts.
10.
CAUTION: Plug all openings. Use new plugs.
Remove the dipstick and oil level indicator tube.
- Release the wiring harness clamp.
- Turn out a bolt.
- Remove and discard the O-ring.
11. Remove the left EGR valve (EGR) and heat exchanger assembly.
- Disconnect the electrical connector.
- Remove the clamp and discard it.
- Release the clamp and disconnect the coolant hose.
- Turn out 5 bolts.
- Choose a bracket.
12. Remove the left exhaust manifold heat shield. Turn out 2 bolts.
13. Remove the heat shield from the turbocharger. Turn out 2 bolts.
14.
CAUTION: Plug all openings. Use new plugs.
Remove the turbocharger oil return line.
- Release the wiring harness clamp.
- Turn out 3 bolts.
- Remove and discard the gasket.
- Remove and discard the O-ring.
15. Release the turbocharger support bracket. Turn out 4 bolts.
16.
CAUTION: Plug all openings. Use new plugs.
Disconnect the turbocharger oil supply line.
- Remove the floor bolt.
- Remove and discard 2 sealing washers.
17. Disconnect the bypass tube of the exhaust system from the left exhaust manifold.
- Loosen and discard 3 nuts.
- Remove and discard the gasket.
18. Remove the left exhaust manifold assembly with turbocharger.
- Loosen and discard 6 nuts.
- Remove and discard the gasket.
19. Remove an inlet branch pipe of a cooling liquid of the block of cylinders.
- Turn out 2 bolts.
- Remove and discard the O-ring.
20. Remove the crankshaft position sensor (TFR).
- Disconnect the electrical connector.
- Reposition the service port cover.
- Turn out a bolt.
21. Remove the EGR valve assembly with the heat exchanger of the right row of cylinders.
- Disconnect the electrical connector.
- Remove the clamp and discard it.
- Release the clamp and disconnect the coolant hose.
- Turn out 4 bolts.
22. Disconnect the electrical connectors of the generator.
- Move the rubber pad.
- Loosen the nut.
23. Remove the generator. Turn out 3 bolts.
24. Remove the right exhaust manifold heat shield. Turn out 3 bolts.
25. Remove an arm of the right support of the engine. Turn out 4 bolts.
26. Remove the generator bracket. Turn out 5 bolts.
27. Remove the right final collector in gathering with a bypass tube of system of release OG.
- Loosen and discard 6 nuts.
- Remove and discard the gasket.
28. Remove the EGR valve coolant line.
- Turn out a bolt.
- Disconnect electrical connector.
- Release from 2 clips.
- Release the clamp.
29. Remove the coolant pump.
- Turn out 3 bolts.
- Remove and discard the O-ring.
30. Remove the auxiliary drive belt idler pulley. Turn out a bolt.
31. Remove the cooling fan pulley. Turn out 3 bolts.
32. Remove the crankshaft pulley. Turn out 6 bolts.
33. Remove the timing belt cover. Completely loosen 16 bolts.
34.
NOTE: Record the installation position of the parts.
Remove 2 low pressure fuel lines. Disconnect the two quick couplers.
35. Disconnect the electrical connector of the engine oil pressure sensor (EOP). Release the wiring harness clamp.
36.
NOTE: Left side shown, right side similar
Disconnect the fuel injector electrical connectors (6 pcs.). Release the 4 cable harness clips.
37. Disconnect the camshaft position sensor electrical connector (SMR). Release the wiring harness clamp.
38. Disconnect the electrical connector of the engine oil temperature sensor. Release the wiring harness clamp.
39.
NOTE: Left side shown, right side similar.
Disconnect the 2 knock sensor electrical connectors (KS).
40. Disunite an electric socket of the gauge of temperature of fuel.
41. Remove the crankcase ventilation oil separator. Disconnect and release 2 ventilation hoses.
42. Disconnect the fuel rail pressure sensor electrical connector (FRP).
43. Disconnect the 2 electrical connectors for the high pressure fuel pump.
44. Remove the engine wiring harness.
- Loosen the nut.
- Release 2 clamps.
45.
CAUTION: Plug all openings. Use new plugs.
NOTE: Right side shown, left side similar
Remove and discard the 2 fuel rail high pressure fuel feed lines. Release 2 clamps.
46.
CAUTION: Plug all openings. Use new plugs.
Remove and discard the intermediate manifold high pressure fuel feed line.
47.
CAUTION: Plug all openings. Use new plugs.
NOTE: Left side shown, right side similar
Remove and discard the 2 fuel rail high pressure fuel feed lines. Release the clamp.
48.
CAUTION: Ensure that the high pressure fuel supply line remains in contact with the fuel injector and fuel manifold until both fittings are disconnected and cleaned. Failure to do so may result in dirt entering the fuel injection system.
CAUTION: Make sure that the fuel injector adapter fitting remains stationary when the high pressure fuel supply lines are released. Failure to do so may result in failure of the fuel injector or fuel injector adapter fitting.
CAUTION: Plug all openings. Use new plugs.
Remove the 6 high pressure fuel feed lines and discard them.
49. Disconnect the fuel return line from the fuel injectors. Remove and discard 6 clips.
50. Remove the two fuel injector bolts.
51. Install the special tool studs.
52.
CAUTION: Make sure the puller tabs are properly engaged with the fuel injector. Failure to follow this instruction may result in damage to the element.
Install the special tool tabs on the studs.
53. Remove the fuel injector.
- Rotate the special tool bolts clockwise evenly.
- Remove the special tool.
- Remove and discard the fuel injector clamp.
- Remove and discard the sealing washer.
54. Remove the remaining fuel injectors.
55.
NOTE: Left side shown, right side similar.
Remove 2 fuel manifolds. Turn out 4 bolts.
56. NOTE: Right side shown, left side similar.
Remove the 2 fuel manifold brackets. Turn out 4 bolts.
57. Remove the high pressure fuel pump drive belt cover. Release 2 clamps.
58. Remove and discard the high pressure fuel pump drive belt tensioner. Turn out a bolt.
59. Remove the high pressure fuel pump drive belt and discard it.
60. Install the special tool on the rear camshaft pulley.
- Rotate the crankshaft so that the special tool is parallel to the engine mounting bracket.
- Screw in and tighten the bolt.
61.
NOTE: Discard the bolt.
Using the special tool, remove the bolt securing the rear camshaft pulley.
62. Remove the special tool. Turn out a bolt.
63. Remove the rear camshaft pulley.
64. Remove the back cover of the high pressure fuel pump drive belt. Loosen 2 bolts completely.
65. Turn out adjusting hairpins of the left cover of the engine.
66. Remove the left valve cover.
- Disconnect the KS electrical connector from the valve cover.
- Completely loosen 13 bolts.
- Remove the fuel line support bracket.
- Remove and discard the gasket.
67. Turn out adjusting hairpins of the right cover of the engine.
- Loosen the nut.
- Turn out a bolt.
- Remove the bracket.
68. Remove the right valve cover.
- Disconnect the glow plug electrical connector from the valve cover.
- Disconnect the KS electrical connector from the valve cover.
- Completely loosen 13 bolts.
- Remove and discard the gasket.
69. Remove the vacuum pump of the brake system.
- Turn out 3 bolts.
- Remove the bracket.
- Remove and discard the gasket.
70. Remove the ventilation duct.
- Turn out a bolt.
- Release the clamp.
71. Remove the turbocharger oil supply line.
- Turn out a bolt.
- Remove and discard 2 o-rings.
72. Remove the coolant outlet of the cylinder head assembly.
- Turn out 4 bolts.
- Remove and discard the O-ring.
73.
CAUTION: Plug all openings. Use new plugs.
Disconnect the fuel line from the fuel cooler.
74.
CAUTION: Plug all openings. Use new plugs.
Remove and discard the fuel injector return line.
75. Turn the crankshaft clockwise to align the crankshaft adjusting hole in the flywheel or faceplate with the hole in the cylinder block.
76. Check up correctness of position of adjusting openings of pulleys of camshafts. If the adjustment holes are not aligned, rotate the crankshaft one full turn clockwise.
77. Block the faceplate with the special tool. Screw in the starter bolt to secure the special tool.
78. Using the special tool, stop the flywheel. Screw in the starter bolt to secure the special tool.
79.
CAUTION: Do not use special tools to lock the camshafts. Failure to do so may result in damage to the engine or special tools.
Loosen the 6 exhaust camshaft pulley bolts.
80. Remove and discard the timing belt tensioner. Turn out a bolt.
81. Remove the 2 intermediate timing belt pulleys.
- Turn out 2 bolts.
- Pick up the plastic shield from the back of the upper intermediate pulley.
82. Remove and discard the timing belt.
83.
NOTE: Left side shown, right side similar.
Remove 2 camshaft pulleys. Turn out 6 bolts.
84. Using the special tool, remove the 2 camshaft pulley hubs. Loosen and discard 2 bolts.
85. Remove the cooling fan drive hub bearing. Turn out 3 bolts.
86. Hold the right secondary timing chain tensioner piston.
- Reposition the secondary timing chain tensioner.
- Insert a pin with a diameter of 1.5 mm (0.060 inch) into the secondary timing chain tensioner piston.
87.
CAUTION: Loosen the camshaft bearing caps evenly and gradually.
Remove the right side camshaft bearing caps. Remove 18 bolts.
88. Remove the camshafts of the right row of cylinders, complete with the timing chain tensioner.
- Turn out 2 bolts.
- Release the right secondary timing chain tensioner.
89. Remove the timing chain tensioner for the right-hand cylinder bank.
90. Remove the camshafts of the right row of cylinders.
- Remove the secondary timing chain from the right camshafts.
- Remove and discard seal.
91.
CAUTION: Do not lay the cylinder head with the mating surface down. Failure to follow this instruction may result in damage to the vehicle.
ATTENTION: The old gasket may only be scraped off with a plastic scraper.
Remove the right row cylinder head assembly.
- Remove and discard 8 bolts.
- Remove and discard the gasket.
92. Hold the left secondary timing chain tensioner piston.
- Reposition the secondary timing chain tensioner.
- Insert a pin with a diameter of 1.5 mm (0.060 inch) into the secondary timing chain tensioner piston.
93.
CAUTION: Loosen the camshaft bearing caps evenly and gradually.
Remove the left camshaft bearing caps. Remove 18 bolts.
94. Remove the camshafts of the left row of cylinders, complete with the timing chain tensioner.
- Release the left secondary timing chain tensioner.
- Turn out 2 bolts.
95. Remove the left side timing chain tensioner for the left cylinder bank.
96. Remove the camshafts of the left row of cylinders.
- Remove the secondary timing chain from the left camshafts.
- Remove and discard 2 seals.
97.
CAUTION: Do not lay the cylinder head with the mating surface down. Failure to follow this instruction may result in damage to the vehicle.
ATTENTION: The old gasket may only be scraped off with a plastic scraper.
Remove the left row cylinder head assembly.
- Remove and discard 8 bolts.
- Remove and discard the gasket.
98. Remove the special tool from the faceplate.
99. Remove the faceplate.
- Lock the faceplate with the special tool.
- Remove 8 bolts.
100. Remove the special tool from the faceplate.
101. Install the special tool.
102.
CAUTION: Loosen the bolts gradually in a criss-cross pattern.
NOTE: Lock the flywheel.
Remove the driven and pressure plates of the clutch. Turn out 6 bolts.
103.
NOTE: Lock the flywheel.
Remove flywheel. Remove 8 bolts.
104. Remove the special tool.
105. Remove the oil cooler assembly.
- Remove 8 bolts.
- Remove and discard the gasket.
106. Remove the high pressure fuel pump. Turn out 4 bolts.
107. Remove the oil pan.
- Remove 14 bolts.
- Remove and discard the gasket.
108. Remove the mesh filter and the oil intake pipe of the oil pump.
- Turn out a bolt.
- Remove and discard 2 o-rings.
109. Remove the oil pan extension.
- Remove 18 bolts.
- Remove and discard the gasket.
Comments on this article