Dismantling
1. Disconnect "negative" battery terminal.
2. Drain the engine coolant.
COOLING SYSTEM: Td4 engine, ADJUSTMENTS, Coolant drain, system flush and fill.
3. Remove hydraulic lifters.
ENGINE - Td4, Intake and exhaust camshafts, Hydraulic lifters, engine kit.
4. Support the engine by placing a jack with a block of wood as a spacer under the sump.
5. Disconnect the connector from the fuel pressure sensor.
6. Remove the rubber bushing of the wire harness from the cylinder head.
7. Disconnect connectors from glow plugs.
8. Disconnect the block from the coolant temperature sensor.
9. Having loosened nuts, disconnect fuel tubes from a fuel stage and the fuel pump. Assemble the fuel pipe support bushings.
CAUTION: Always plug fittings and openings to keep dirt out of the system.
10. Turn away 2 bolts and remove a fuel stage.
11. Turn away three bolts and take away a branch pipe of system of cooling from a head of cylinders. Dispose of the gasket.
12. Turn away a collar and disconnect a hose of a broad tank from a distributive pipe of system of cooling.
13. Loosen the clamps and remove the hose from the turbocharger outlet.
14. Turn away a bolt of fastening of a fuel stage to a basic arm.
15. Turn away a bolt of fastening of an output hose of a turbocharger to a basic arm.
16. Loosen the clamp that secures the pipe of the exhaust gas recirculation system to the heat exchanger and remove the clamp from the heat exchanger.
17. Turn away three bolts of fastening of the heat exchanger of cooling EG (recycling systems) to the cylinder head and to the eye.
18. Turn away a bolt of fastening of an output hose of a turbocharger to a distributive tube of system of cooling.
19. Turn away a bolt of fastening of an output hose of a turbocharger to an arm on a final collector.
20. Turn away three bolts of fastening of a heat-shielding screen to a distributive tube of system of cooling.
21. Turn away a bolt, remove a pipe of system of cooling from the case of the thermostat and utilize a lining.
22. Remove the heat shield.
23. Turn out and utilize 2 screws of fastening of the vacuum pump.
24. Remove the vacuum pump and take it aside. Dispose of the gasket.
25. Turn away 3 bolts of fastening of a turbocharger to a final collector. Dispose of the gasket.
26. Turn away a bolt of fastening of a collar of a tube of the hydraulic booster to an eye.
27. Turn away two bolts and remove an eye.
28. Remove the camshaft drive chain from the sprockets.
29. Remove and dispose of the clamps of the damper of the gas distribution chain.
30. Remove the chain guides.
Access to the guide from the intake side will be better with the cylinder head removed.
31. Remove 5 Allen screws and one cylinder head bolt through the front cover (timing cover).
32. In the specified sequence, unscrew and dispose of the 11 cylinder head bolts.
33. With the help of a partner, remove the cylinder head.
Care must be taken not to damage the protruding glow plugs.
34. 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.
TECHNICAL DATA, Engine - Diesel Td4.
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 a connecting rod-piston group was replaced, then for the correct choice of gasket thickness, it is necessary to measure the protrusion of the pistons.
ENGINE - Td4, ADJUSTMENTS, Checking piston protrusion with cylinder head removed.
5. After making sure that the sealant strips on the gasket are not damaged, install the gasket on the cylinder block.
6. Lightly coat the 12 new cylinder head bolts with engine oil.
7. Using a partner, install the cylinder head and tighten the 11 bolts in sequence to 80 Nm. The long bolt should be in the position indicated by number 11 as shown in the illustration. Loosen all bolts half a turn and retighten them. Tightening torque 50 Nm. Using an angle torque wrench, tighten all bolts in sequence by 90°and again by 90°.
8. Tighten the last bolt, which is 41 mm long and in position 12, to 110 Nm.
9. Tighten bolts of fastening of a head of cylinders to a cover of the gas distribution mechanism. Tightening torque 5 Nm.
10. Wipe the dampers of the gas distribution chain.
11. Replace the chain guides so that the guide on the intake manifold side 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. Install the eye and tighten the bolts to 20 Nm.
15. Tighten the bolt securing the hydraulic booster tube to the eye to 10 Nm.
16. Install the turbocharger on a new gasket and tighten the bolts of its fastening. Tightening torque 45 Nm.
17. Clean the vacuum pump and mating surfaces of dirt.
18. Install a new seal on the vacuum pump, install the vacuum pump and tighten the new mounting bolts to 22 Nm.
19. Wipe a distributive pipe of system of cooling and mating surfaces.
20. Install the heat shield.
21. Put a new seal on the distribution pipe of the cooling system, install the pipe on the thermostat housing and tighten the bolt to 8 Nm.
22. Tighten the heat shield mounting bolts. Tightening torque 8 Nm.
23. Reinstall the EGR heat exchanger and fuel rail and tighten the mounting bolts. Tightening torque 25 Nm.
24. Put on a collar of fastening of a tube of bypass OG and tighten the screw.
25. Route the turbocharger outlet hose and secure it. Tightening torque for M8 bolts - 25 Nm, M6 bolts - 10 mm.
26. Screw in the bolt securing the fuel rail to the support bracket and tighten it. Tightening torque 10 Nm.
27. Put on the TKR outlet air hose and tighten the clamps.
28. Attach a hose to a broad tank and fix it with a collar.
29. Wipe the coolant pipe and mating seat.
30. Install a new gasket on the cooling system pipe and tighten the bolts to 8 Nm.
31. Install the fuel rail in place and tighten the mounting bolts. Tightening torque 24 Nm.
32. Install the high pressure fuel pipe and support sleeve, tighten the nut on the pipe. Tightening torque 30 Nm.
33. Connect the connector to the coolant temperature sensor (ECT).
34. Connect the connectors to the spark plugs.
35. Connect the connector to the fuel pressure sensor.
36. Insert the rubber bushing of the wiring harness into the cylinder head.
37. Install hydraulic lifters.
ENGINE - Td4, Intake and exhaust camshafts, Hydraulic lifters, engine kit.
38. Attach "negative" battery terminal.
39. Fill the engine with coolant.
COOLING SYSTEM: Td4 engine, ADJUSTMENTS, Coolant drain, system flush and fill.
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