Contents: Removal ⇩ Installation ⇩
Before disconnecting the battery, make sure that all precautions specified for this procedure have been followed.
GENERAL INFORMATION, Precautions when working with electrical equipment.
Removal
1. Place the car on a lift.
2. Disconnect the negative cable from the battery.
3. Remove the battery cover, unscrew the nut and remove the positive terminal from the battery.
4. Remove the air intake receiver.
HEATING AND VENTILATION, REPAIR WORKS, Air intake box.
5. Remove the lower protective cover.
EXTERIOR PARTS, REPAIR WORK, Engine protection - front.
6. Drain the coolant from the engine.
COOLING SYSTEM: Td6, ADJUSTMENTS AND MAINTENANCE, Draining the coolant, flushing the system and filling.
7. Drain the oil from the engine.
MAINTENANCE, SERVICE OPERATIONS, Engine oil and oil filter - Td6 engine.
8. Remove the exhaust system.
EXHAUST MANIFOLD AND EXHAUST SYSTEM: Td6 engine, REPAIR WORK, Exhaust system and suspension of system components.
9. Remove the front propeller shaft.
DRIVE SHAFTS, REPAIR WORK, Cardan shaft - front.
10. Remove the O-ring from the right wheel drive shaft support bearing housing.
DRIVE SHAFTS, REPAIR WORK, Sealing ring - differential cover with drive shaft bearing support.
11. Remove the differential seal.
FRONT AXLE MAIN GEAR AND DIFFERENTIAL, Main gear with differential assembly - Td6, Seal - differential output shaft.
12. Remove the soundproofing casing from the engine.
TD6 ENGINE, REPAIR WORK, Engine soundproofing casing.
13. Remove the air filter.
ENGINE MANAGEMENT SYSTEM Td6:, REPAIR WORK, Air cleaner filter element.
14. Remove the accessory drive belt.
ENGINE STARTING AND BATTERY CHARGING SYSTEM, REPAIR WORK, Attachment drive belt - Td6 engine.
15. Remove the starter.
ENGINE STARTING AND BATTERY CHARGING SYSTEM, REPAIR WORK, Starter - Td6 engine.
16. Loosen the clamp and disconnect the air hose leading to the air-to-air cooler from the EGR valve. Discard the clamp.
CAUTION: To prevent contamination, install plugs on open connectors.
17. Loosen the clamp and disconnect the air hose from the air intercooler. Remove the air hose.
18. Loosen the clamp and disconnect the air hose from the turbocharger. Discard the clamp.
CAUTION: To prevent contamination, install plugs on open connectors.
19. Disconnect the vacuum hose from the turbocharger bypass valve.
CAUTION: To prevent contamination, install plugs on open connectors.
20. Remove the clamp, disconnect the turbocharger air hose from the intercooler and take out the hose.
21. Disconnect the vacuum hose from the vacuum receiver.
CAUTION: To prevent contamination, install plugs on open connectors.
22. Release the vacuum hoses from the supporting clamps.
23. Unscrew the 3 bolts securing the air conditioning compressor, move the compressor to the side and secure it.
24. Unscrew the 4 bolts securing the power steering pump, move the pump away and secure it.
25. Loosen the clamp and disconnect the upper radiator hose from the cooling system outlet pipe.
26. Loosen the clamp and disconnect the lower radiator hose from the thermostat housing.
27. Loosen the clamp and disconnect the cooling system hose from the EGR heat exchanger.
28. Loosen the clamp and disconnect the expansion tank hose from the cooling system pipeline.
29. Loosen the clamp and disconnect the heater hose from the cooling system pipe.
30. Loosen the clamp and disconnect the hose from the heater radiator tap.
31. Loosen the nut securing the transmission oil cooling system hoses to the engine sump.
32. Unscrew the 3 bolts securing the transmission oil cooling heat exchanger, move the heat exchanger to the side and secure it.
33. Release the three clamps from the vacuum hose on the left engine mount.
34. Disconnect the vacuum pump hose from the tee.
CAUTION: To prevent contamination, install plugs on open 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 supporting clamp.
38. Loosen the clamp and disconnect the fuel hose from the fuel filter and the fuel flow regulator hose from the tee.
CAUTION: Before disconnecting or removing engine components, clean any dirt from areas immediately adjacent to mating surfaces or connectors. To prevent contamination, plug 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 open connectors.
41. Release the transmission breather hoses from the supporting clamps and move them to the side.
42. Loosen the clamp and disconnect the brake system vacuum hose.
CAUTION: To prevent contamination, install plugs on open connectors.
43. Unscrew the 10 mounting bolts of the mounting box cover and remove the cover.
44. Unscrew the nut securing the ground wire 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 gearbox control unit.
48. Disconnect the glow plug control unit support from the mounting box and disconnect the connector.
49. Disconnect the positive wire.
50. Remove the fuse and relay box from the mounting box.
[The material was taken from a website: LRman.ru]
51. Disconnect the connector.
52. Remove the wire harness feedthrough seals from the junction box.
53. Turn and disconnect the connector from the gearbox.
54. Release the transmission wiring harness from the supporting clamps.
55. Remove the plug from the drive disk housing cover to gain access to the torque converter mounting bolts.
56. Using the LRT-12-212 tool, rotate the crankshaft and alternately unscrew the 3 bolts securing the drive disk to the torque converter.
57. Unscrew the bolt securing the hatch to the gearbox.
58. Disconnect the connector from the boost pressure sensor.
59. Loosen the boost pressure sensor mounting bolt and remove the sensor. Discard the gasket.
CAUTION: To prevent contamination, install plugs on open connectors.
60. Install LRT-12-216 hooks on the rigging chains and hook them to the engine lifting eyes.
61. Unscrew the 2 nuts securing the engine support brackets to the supports.
62. Raise the engine until it is completely clear of the mounts.
63. Install the support stand under the gearbox.
64. Unscrew the 4 bolts securing the gearbox to the engine sump and remove the plate.
65. Unscrew the 4 bolts securing the gearbox to the engine.
66. Release the engine from the guide pins, carefully lift it and move it away from the vehicle.
CAUTION: Make sure the torque converter remains on the transmission.
67. Remove the hatch.
Installation
1. Wipe 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, the dowel pins and the dowel seats.
4. Wipe the hatch.
5. Install the hatch on the pins.
6. Using a partner, carefully connect the engine to the gearbox. Ensure that the torque converter centering sleeve fits precisely and that the pins fit into the sockets.
7. Screw in the gearbox-to-engine mounting bolts and tighten them. Tightening torque 45 Nm.
8. Remove the hydraulic strut from under the gearbox.
9. Lower the engine onto the supports.
10. Remove the rigging chains from the engine.
11. Screw on 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 gearbox mounting bolts to the engine sump. Tightening torque 22 N·m.
13. Screw in the hatch mounting bolt and tighten it. Tightening torque 10 Nm.
14. Screw in the drive disk mounting bolts to the torque converter and tighten them. Tightening torque 45 N·m.
15. Install the plug on the hatch.
16. Connect the connector to the gearbox and secure the wiring harness in the clamps.
17. Route the engine harness to the junction box, connect the connectors and the positive wire. Connect the connector to the glow plug control unit.
18. Install the fuse box, relay block into the mounting box and secure the glow plug control unit to it.
19. Connect the connectors to the engine and gearbox control units.
20. Place the ground wire on the stud, screw on the nut and tighten it. Tightening torque 25 Nm.
21. Install the wire harness feedthrough seals onto the junction box.
22. Replace the cover of the mounting box and tighten it with bolts. Tightening torque 2 Nm.
23. Connect the brake system vacuum hose and secure it with a clamp.
24. Install the starter.
ENGINE STARTING AND BATTERY CHARGING SYSTEM, REPAIR WORK, Starter - Td6 engine.
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. Secure the wire harness in the clamps.
31. Connect the vacuum supply hose and secure it with clamps.
32. Wipe the transmission oil cooling heat exchanger and the mating surface.
33. Install the engine oil cooling heat exchanger in place and tighten its mounting bolts.
34. Tightening torque 10 N·m. Tighten the transmission oil cooling system hose fastening nut.
35. Place the hose onto the differential breather and secure it with the clamp.
36. Secure the transmission breather hoses to the clamps.
37. Wipe the boost pressure sensor and its installation location.
38. Place a new gasket on the sensor and secure it with a bolt to the intake manifold. Tightening torque 8 Nm.
39. Connect 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. Connect 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. Connect the lower radiator hose and secure it with a clamp.
44. Connect the coolant 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 N·m and the M6 bolts to 10 N·m.
47. Wipe the air conditioning compressor bracket and mating surface.
48. Install the compressor in place, put on the ground wire and tighten the mounting bolts. Tightening torque 25 N·m.
49. Connect the vacuum hose to the turbocharger bypass valve.
50. Connect the vacuum hose to the vacuum receiver.
51. Secure the vacuum hose to the clamps.
52. Wipe the turbocharger pipe and the mating part of the air hose.
53. Install the hose connecting the turbocharger to the air-to-air intercooler. Use a new clamp. Tighten the clamp to 6 N·m.
54. After waiting 15 minutes, tighten the clamp securing the air hose to the turbocharger again. Tightening torque 6 Nm.
55. Wipe the pipe on the EGR valve and the mating part of the intake hose.
56. Using a new clamp, secure the air hose from the air-to-air cooler to the EGR valve. The clamp tightening torque is 6 N·m.
57. After waiting 10 minutes, tighten the clamp securing the air hose to the valve again. Tightening torque 6 N·m.
58. Install the accessory drive belt.
ENGINE STARTING AND BATTERY CHARGING SYSTEM, REPAIR WORK, Attachment drive belt - Td6 engine.
59. Install the air filter.
ENGINE MANAGEMENT SYSTEM Td6:, REPAIR WORK, Air cleaner filter element.
60. Install the engine noise insulation cover.
TD6 ENGINE, REPAIR WORK, Engine soundproofing casing.
61. Install the differential seal.
FRONT AXLE MAIN GEAR AND DIFFERENTIAL, Main gear with differential assembly - Td6, Seal - differential output shaft.
62. Install the right wheel drive shaft support bearing housing O-ring.
DRIVE SHAFTS, REPAIR WORK, Sealing ring - differential cover with drive shaft bearing support.
63. Install the front propeller shaft.
DRIVE SHAFTS, REPAIR WORK, Cardan shaft - front.
64. Install the exhaust system.
EXHAUST MANIFOLD AND EXHAUST SYSTEM: Td6 engine, REPAIR WORK, Exhaust system and suspension of system components.
65. Fill the engine with oil.
MAINTENANCE, SERVICE OPERATIONS, Engine oil and oil filter - Td6 engine.
66. Install the lower casing.
EXTERIOR PARTS, REPAIR WORK, Engine protection - front.
67. Install the air intake receiver.
HEATING AND VENTILATION, REPAIR WORKS, Air intake box.
68. Place the positive battery cable terminal onto the pole piece, tighten the nut to 18 N·m and replace the cover.
69. Connect the negative cable to the battery.
70. Fill the engine with coolant.
COOLING SYSTEM: Td6, ADJUSTMENTS AND MAINTENANCE, Draining the coolant, flushing the system and filling.
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