Removal and installation of a head of the block of cylinders

Cylinder head bolt tightening sequence

Withdrawal

Attention! The engine must be cold when removing the cylinder head (wait 6 hours after turning off the engine). Disconnect the ground wire from the battery and remove the air filter.

1. Remove the sheet casing from the bottom of the engine, drain the coolant (by substituting the appropriate container). Disconnect the coolant hoses: lower from the radiator and upper from the pump.

2. Disconnect the pipes from the expansion tank of the cooling system, from the cylinder head, from the interior heating system and the vacuum line from the vacuum pump.

3. Disconnect the wire and current bus from the glow plugs, as well as the rest of the electrical wires.

4. Disconnect the idle speed control cable from the engine cylinder head.

5. Disconnect fuel injection and return lines from injectors, unscrew injectors and glow plugs from cylinder head.

6. Remove the vacuum pump together with the drive V-belt and remove the alternator.

7. Detach the alternator mounting frame from the intake manifold and remove the V-belt.

8. Disconnect the oil supply pipe from the cylinder head and the front exhaust pipe from the exhaust manifold.


9. Remove the cylinder head cover and valve lever shaft.

10. Remove the push rods.

11. Remove the cylinder head bolts in reverse order of tightening.

12. Remove the cylinder head together with the manifolds: intake and exhaust.

13. Remove head gasket.

Installation

1. Thoroughly clean the gasket contact surfaces in the cylinder block and head, as well as the holes for the cylinder head bolts.

2. Screw in dowel pins 21.083.



3. Install a new cylinder head gasket of the correct thickness (arrow), by checking the accuracy of its installation. Carefully install the head, tighten the mounting bolts by hand and replace the two centering pins with the two cylinder head bolts.

4. Lubricate the ends of the tappet rods with engine oil and position them so that they engage with the same tappets that they worked with before removing the cylinder head. Install the oil supply pipe gasket and valve lever shaft. Tighten the bolts and nuts of the valve lever axle holders.

5. Tighten the cylinder head bolts following the sequence, recommended torques and tightening method (see subsection 4.2.1.5).


6. Adjust valve clearance.

7. Screw in glow plugs.

8. Install the generator and connect the electrical wires.

9. Install the injectors and connect their pipelines.

10. Connect the cooling system hoses and fill the cooling system (see subsection 4.2.11.5.2).