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4.6. Repair of 6-cylinder diesel engines

 PERFORMANCE ORDER

  1. Uncover a broad tank of the cooling system.
  2. Remove from a turbocompressor the inlet pipeline together with the MAF sensor.
  3. Remove the top cover of the engine.
  4. Remove the rechargeable battery, give fixture of the assembly block of safety locks and shift it aside.
  5. Remove the holder of the battery.
  6. Poddomkratte the car also remove the lower protection cover of a motive compartment.
  1. Weaken a tension of a belt of the drive of auxiliary units and remove it. Then slightly give a back bolt of fastening of the generator. Mark the direction of the movement of a belt if its further use is supposed.
  1. Empty the engine cooling system.
  2. Cut a coupler of an electrical wiring of the sensor of level of motive oil.
  3. Turn out a forward bolt of a forward support of the power unit (10 on an illustration).

Bolt (10) of fastening of a forward support and delivery tube of a turbocompressor (11).

  1. Disconnect a delivery tube of a turbocompressor from the intercooler (11 on an illustration).
  2. Turn out bolts of fastening of an arm of an exhaust pipe and give nuts on a joint of an exhaust pipe.
  3. Remove a delivery hose with a tube from the top inlet pipeline.
  4. Remove the catalytic converter.
  5. Cut a coupler on a hose of a radiator and remove the top hose of a radiator.
  6. Remove the socket and a coupler from a guide of the probe of level of motive oil. Remove a guide.
  7. Turn out the top bolt of a lifting eye and weaken the lower bolt. Take a lifting eye aside.
  8. Separate sockets, cut a cable coupler and remove a casing of fans of the cooling system.
  9. Turn out the lower screw and remove a lifting eye.
  1. Give a nut of a back support of the power unit.
  1. Weaken quick disconnect connections of fuel lines (22 on an illustration). Wipe the flowed-out fuel rags.
  1. Unload an engine support, having propped up it a jack. Remove the right support of the engine with top an arm and a pillow. Lift the engine a little more to get access of a bolt of fastening of an arm (23 on an illustration).
  1. Uncover a GRM drive belt.
  1. Install the piston of the first cylinder in the provision of VMT of the end of a step of compression. For this purpose combine tags on a pulley of a bent shaft and on cogwheels of the camshaft and TNVD with marks in the engine. If tags on a belt not accurate, put them anew.
  1. Unload a roller of a natyazhitel (to the right of a bent shaft), having turned it and having inserted into an opening in it a core with a diameter of 6 mm. Turn out a bolt of fastening of a roller, at the same time extending it on themselves.
  2. Shoot a belt of the GRM drive and an intermediate video (over a bent shaft).
  1. Remove the pump GUR with an arm.
  1. Separate sockets of an electrical wiring of the engine and remove it aside (30 on сопр. illustrations).
  1. Remove the top section of the inlet pipeline and an arm of a turbocompressor (31 on an illustration).
  2. Remove the turbocompressor thermofilter (32 on an illustration).
  1. Remove a clamp and disconnect the operating rod of a vacuum box of a turbocompressor (33 and 34 on an illustration).
  1. Disconnect a vacuum hose (35 on an illustration) and separate the socket (36).
  2. Disconnect from a turbocompressor the giving tube (37 on an illustration).
  1. Disconnect oil and water tubes, and also the vacuum block from a turbocompressor. Remove a turbocompressor.
  1. Remove fuel tubes and the distributive highway.
  1. Remove thermofilters over a final collector. Lower a jack to remove the back thermofilter.
  2. Remove the pipe connecting blocks of cylinders.
  3. Disconnect an engine cooling system tube from a cover of a head of cylinders.
  4. Remove hoses of ventilation of a case.
  5. Disconnect the returnable fuel line from forward and back blocks of cylinders.
  6. Disconnect the giving tubes and remove holders of the giving and returnable fuel tubes from a back head of cylinders.
  7. Uncover heads of cylinders.
  1. Weaken quick disconnect connections in a back part of a bed of the camshaft then remove arms of nozzles (48 on an illustration).
  1. Remove nozzles and returnable fuel lines (49 on an illustration).
  1. Turn out bolts of fastening of covers of cogwheels and a bolt under a cover of a forward number of cylinders (50 on an illustration).
  1. Turn out the hairpins holding arms of nozzles (51 on an illustration).
  2. Remove hoses of the vacuum pump both back and forward beds of camshafts.
  1. Turn out bolts of fastening of the EGR valve to a cooling system tube (53 on an illustration) and remove knot aside.
  1. Turn out a bolt of fastening of a tube of ventilation of a case to the inlet pipeline of a forward number of cylinders (54 on an illustration).
  2. Turn out bolts of fastening of a tube of the cooling system to a head of cylinders (55 on an illustration).
  3. Remove cable channel of the forward inlet pipeline (56 on an illustration).
  4. Remove cooling system hoses from the back block of cylinders.
  5. Turn out a bolt of the top fastening of the generator.
  1. Remove heads of cylinders from blocks of cylinders together with final collectors and inlet pipelines.

Installation

 PERFORMANCE ORDER

  1. Clear the interfaced surfaces and combustion chambers. Blow carving openings under bolts of fastening of heads of cylinders compressed air to remove from them oil and dirt.
  2. Make sure that guides are installed in blocks of cylinders.
  3. Establish heads of cylinders with new laying and bolts.

Pay attention that bolts have various length, roll them in the corresponding openings. Make sure that laying is laid on the corresponding blocks of cylinders (on laying tags of "L" – left, - and "R" – right are put). Thickness of laying is chosen according to Specifications.

  1. Tighten bolts of fastening of heads of cylinders in the sequence, return specified illustrations of item 54 (Removal) and with the required efforts (see Specifications).
  2. Further installation is made in the sequence, the return to an order of dismantle of components. Pay attention to the next moments:
    • Tighten fixture according to requirements of Specifications;
    • Use the new giving TNVD tube;
    • Use new consolidations of nozzles;
    • At installation of a cover of a head of cylinders use new laying, and also apply sealant (No. 87 81 841 according to the Saab catalog) on surfaces;
    • At installation of the pipe connecting blocks of cylinders use new laying and grease fixing bolts with means of Molycote 1000;
    • Grease with means of Molycote 1000 fixture of a turbocompressor, arm of an exhaust pipe and its connection;
    • Before installation of a belt of the GRM drive make sure that tags on cogwheels and on a pulley of a bent shaft are combined with tags on the engine. After installation of a belt turn the engine on 2 whole revolutions and again make sure that adjusting tags of VMT coincide.
  3. Upon termination of installation fill the cooling system and the lubrication system. Start the engine and check it for leak of oil and cooling liquid.