Note: This engine is equipped with ceramic glow plugs. To avoid damage, do not remove the glow plugs unless necessary.
1. Drain the coolant.
2. Remove the air intake duct (see above).
3. Removing the bracket and accelerator lever
a) Disconnect the accelerator lever from the fuel injection pump.
b) Unscrew the three mounting bolts and remove the bracket.
4. Remove the high pressure fuel lines (see below).
5. Unscrew the oil dipstick tube mounting nut, remove the tube and sealing ring.
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6. Removing the intake manifold.
a) Disconnect:
- Sensor connectors on the head;
- Two height compensator hoses (if installed).
b) Unscrew the 7 manifold mounting nuts, remove the manifold and 4 gaskets.
Hose Location: 1 - vacuum pump, 2 - boost pressure sensor, 3 - gas filter, 4 - load compensation drive valve, 5 - load compensation drive, 6 - boost corrector, 7 - altitude compensator valve, 8 - overflow nipple.
7. Unscrew the 2 mounting nuts and remove the water pipe.
8. Disconnect the return fuel line, unscrew the 4 nuts securing the drain pipe on the injectors. Remove the drain pipe and 4 sealing washers.
9. Remove the fuel injectors. Mark the injectors by cylinder numbers.
10. Unscrew the bolt and two nuts securing the heater inlet pipe, remove the pipe and gasket.
11. Remove the vacuum hose and tube assembly.
12. Remove the turbocharger and intake manifold (see section "Turbocharger")
13. Unscrew the two bolts and nut securing the heater outlet pipe, remove the pipe and gasket.
14. Remove the timing belt and gears.
15. Remove the rear timing belt cover.
16. In several steps and in the order shown in the figure, unscrew the camshaft bearing cap mounting bolts, remove the caps and the camshaft.
17. Unscrew the 18 head mounting bolts in the order shown in the figure.
Lift the cylinder head off the cylinder block pins and place it on wooden blocks.
Note: If you have difficulty removing the head, pry the cylinder head off with a screwdriver.
Caution: Be careful not to damage the mating surfaces of the cylinder block and cylinder head.