Removing
1. Remove the top decorative engine cover (see relevant section in this chapter).
2. Remove the sound insulation on the sections of the high pressure fuel pump, if installed.
Attention.
- The plugs must be disconnected from the glow plugs carefully.
- If the plug is damaged during disconnection, the entire wiring harness, including the plugs, would have to be replaced (plugs cannot be replaced individually). It is possible to make your work easier with a No. 12 open-end wrench.
3. Disconnect the wiring harness connector from the charge pressure regulator position sender -G581- (arrow) on the turbocharger vacuum reservoir, remove the fuel line from the mounting as shown in the figure below.
4. Unscrew the screw shown in the figure below (3).
5. Remove engine mount bracket (grey).
6. Remove the high pressure fuel line between the high pressure pump (1) and fuel rail injection system (3), as shown in the figure below.
Note.
- The preferred sequence for loosening the high pressure lines on cylinders is 4-3-2-1.
- During loosening, hold the high-pressure pipe connection on the pumping stations (plunger) sections.
7. Remove the pressure line between the fuel rail and the plunger pairs.
8. Loosen the elastic collar (arrow) and disconnect the tube from the fuel rail assembly as shown in the figure below.
9. Disconnect wiring harness connector at fuel pressure control valve -N276- (arrow), as shown in the figure below.
10. After removing the wiring harness from the rail, set it aside.
11. Disconnect wiring harness connector at fuel pressure sender -G247- (IN), as shown in the figure below.
12. Disconnect the vacuum wire on the cylinder head cover (A), shown in the figure below.
13. Unscrew the screws shown in the figure below (arrows), remove the fuel rail assembly.
14. Unscrew the fixing screws on the intake manifold (arrows), lay the fuel return line aside.
15. Disconnect the wiring harness connector from the fuel injectors (A), as shown in the figure below.
16. Loosen the fuel return connections using a screwdriver and pliers as shown in the figure below.
17. Disconnect the fuel return connections from the fuel injectors by pulling them in the direction of the arrow, as shown in the figure below.
18. After removing the entire fuel return line, lay it on the inlet gas line.
19. To take the remained vacuum wires from the holder on a cover of a head of the block of cylinders.
20. Remove the upper part of the timing belt cover.
21. Remove the air bleed line between the cylinder head cover and the air intake sleeve. To do this, press the quick couplings.
22. Remove the fuel injectors assembly.
23. Remove the cylinder head cover bolts.
24. Remove the cylinder head cover. To do this, release the cylinder head cover from the latches (arrows) rear timing belt guard as shown in the figure below.
Installation
1. Installation is made in sequence, return to removal.
Note. If damaged or leaking, the cylinder head cover seal must be replaced.
2. Hand-tighten the cylinder head cover bolts in sequence (1...6).
3. Screws should be tightened in sequence (1...6) with a tightening torque of 10 Nm.
4. Make sure that the cylinder head cover is correctly attached to the toothed drive belt housing.
Note. For the sake of clarity, the figure below does not show the camshaft drive gear.
To do this, use a screwdriver to press the casing of the toothed drive belt at the location of the clamps (arrows) against the cylinder head cover so that the clips click into each other.
5. Check free play between hub and toothed belt guard
6. Install fuel injectors (for details, see the relevant section in chapter Engine power and control system).