Spare part engine block To remove - To fit
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Spare part engine block To remove - To fit
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Warning
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The work involved in removing the fuel pipe requires working with the vehicle's fuel system. The following points should therefore be heeded in conjunction with these measures:
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• Have a class BE fire extinguisher on hand! Be aware of the risk of sparks, i.e. in connection with electric circuits, short-circuiting, etc.
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• Absolutely No Smoking!
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• Ensure good ventilation! If there is approved ventilation for evacuating fuel fumes then this must be used.
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• Wear protective gloves! Prolonged exposure of the hands to fuel can cause irritation to the skin.
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• Wear protective goggles.
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Important
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Be particulary observant regardning cleanliness when working on the fuel system. Loss of function may occur due to very small particles. Prevent dirt and grime from entering the fuel system by cleaning the connections and plugging pipes and lines during disassembly. Use 82 92 948 Plugs, A/C system assembly. Keep components free from contaminants during storage.
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3.
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Remove the hose to the charge air pipe from the turbo.
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4.
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Detach the heat shield from the turbo.
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5.
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Remove the large lower right-hand trailing wheel for the belt circuit.
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6.
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Remove the idler pulley and belt tensioner.
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7.
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Remove the bracket for the right-hand engine mounting.
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8.
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Remove the pressure plate and clutch plate.
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9.
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Remove the flywheel.
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10.
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Remove the upper intake manifold.
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11.
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Remove the turbo bracket.
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12.
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Remove the heat shields from the front intermediate exhaust pipe and the exhaust manifold.
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13.
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Remove the heat shields from the rear intermediate exhaust pipe and the exhaust manifold.
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14.
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Remove the turbocharger's coolant pipe and oil intake manifold from the turbocharger.
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15.
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Remove the screws to the turbocharger's oil pipe from the cylinder block as well as the EGR pipe from the EGR cooler.
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16.
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Remove the turbocharger with intermediate exhaust pipe as one unit.
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17.
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Remove the front and rear exhaust manifolds.
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18.
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Remove the fuel pipe and the fuel distributor.
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19.
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Remove the EGR valve along with the EGR pipe with water jacket and the pipe to the turbocharger.
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20.
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Lift up the EGR valve slightly and remove the coolant hoses.
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21.
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Remove the crankcase ventilation hoses.
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22.
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Remove coolant pipes and hoses.
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23.
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Remove the oil trap's pipe and hose.
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24.
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Remove the fuel intake manifold from the fuel pump and engine as well as the return fuel pipe and hose from the fuel pump and engine.
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25.
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Remove the front intake manifold.
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26.
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Remove the rear intake manifold.
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27.
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Remove the wiring harness from the injection pump and the glow plug.
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28.
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Remove the glow plugs.
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29.
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Remove the angled pipe for the crankcase ventilation.
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30.
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Remove the dipstick guide tube.
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31.
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Remove the front lifting eye.
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32.
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Remove the power steering pump bracket.
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33.
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Remove the coolant pipe from the cylinder block and the oil cooler.
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34.
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Remove the thermostat cover.
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35.
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Remove the bolts to the coolant pipes from the engine block (x 3)
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36.
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Remove the coolant pipe between the cylinder heads and the coolant pipe to the oil filter housing.
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37.
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Remove the return oil hose between the oil sump and timing cover.
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38.
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Remove the vacuum pump.
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39.
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Remove the coolant pipe and coolant manifold from the left-hand side of the engine.
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40.
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Remove the oil filter housing.
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41.
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Fit the front lifting eye.
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42.
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Lift away the removed engine from the work surface.
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1.
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Unpack the new spare part and remove the plugs and transport protection.
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2.
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Use new gaskets and O-rings when fitting.
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3.
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Place the new engine on a work station. Remove the front lifting eye and the bracket for the power steering pump.
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4.
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Fit the oil filter housing.
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5.
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Fit the coolant manifold and coolant pipe to the left-hand side of the engine.
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6.
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Fit the vacuum pump.
Tightening torque: 8 Nm (6 lbf ft)
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7.
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Fit the idler pulley and belt tensioner.
Tightening torque: 25 Nm (18 lbf ft)
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8.
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Fit the return oil hose between the oil sump and timing cover.
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9.
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Fit the coolant pipe between the cylinder heads. Use new O-rings.
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10.
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Fit the coolant pipes to the cylinder block and oil filter housing (x3).
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11.
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Fit the thermostat cover.
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12.
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Fit the coolant pipe to the cylinder block and oil the cooler.
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13.
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Fit the power steering pump bracket.
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14.
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Fit the front lifting eye.
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15.
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Fit the dipstick guide tube.
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16.
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Fit the angled pipe for the crankcase ventilation.
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17.
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Fit the glow plugs.
Tightening torque: 16 Nm (12 lbf ft)
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18.
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Fit the wiring harness to the injection pump and the glow plug.
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19.
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Fit the front intake manifold.
Tightening torque: 31 Nm (23 lbf ft)
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20.
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Fit the rear intake manifold.
Tightening torque: 31 Nm (23 lbf ft)
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21.
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Fit the fuel intake manifold from the fuel pump and engine as well as the return fuel pipe and hose from the fuel pump and engine.
Tightening torque, return fuel pipe to pump 25 Nm (18 lbf ft)
Tightening torque, fuel intake manifold to pump 25 Nm (18 lbf ft)
Tightening torque, fuel intake manifold to bracket 35 Nm (26 lbf ft)
Tightening torque, other fuel pipe banjo screws 20 Nm (15 lbf ft)
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22.
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Fit the oil trap's pipe and hose.
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23.
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Fit the coolant pipes and hoses.
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24.
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Fit the crankcase ventilation hoses.
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25.
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Fit the coolant hoses to the EGR valve.
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26.
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Fit the EGR valve along with the EGR pipe with water jacket and the pipe to the turbocharger.
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27.
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Fit the fuel rail and fuel pipes. Make sure the protective sleeve on the connector is fitted correctly.
Tightening torque, fuel rail: 25 Nm (19 lbf ft)
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28.
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Fit the front and rear exhaust manifold.
Tightening torque: 52 Nm (38 lbf ft)
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29.
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Fit the turbocharger with intermediate exhaust pipe as one unit.
Tightening torque, intermediate exhaust pipe nuts 21 Nm (15 lbf ft)
Tightening torque, turbocharger bolts 52 Nm (38 lbf ft)
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30.
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Fit the screws for the turbocharger's oil pipe to the cylinder block as well as the EGR pipe to the EGR cooler.
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31.
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Fit the turbocharger's coolant pipe and oil intake manifold to the turbocharger.
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32.
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Fit the heat shields to the rear intermediate exhaust pipe and the exhaust manifold.
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33.
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Fit the heat shields to the front intermediate exhaust pipe and the exhaust manifold.
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34.
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Fit the turbo bracket.
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35.
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Fit the upper intake manifold.
Tightening torque 21 Nm (23 lbf ft)
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36.
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Fit the flywheel. Tighten the bolts alternately.
Tightening torque: 118 Nm (87 lbf ft)
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38.
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Fit the bracket for the right-hand engine mounting.
Tightening torque: 47 Nm (35 lbf ft)
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39.
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Fit the heat shield onto the turbo.
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40.
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Fit the hose to the charge air pipe on the turbo.
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