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Total demolition
Before starting disassembly, thoroughly clean the outside of the engine. Plug all openings of the engine clean cloths to prevent the ingress of foreign bodies into the engine. The engine has a top position of the camshaft. Camshaft drive toothed belt. The cylinder block is cast iron, aluminum cylinder head. Compared with diesel engines, which are previously installed, it has a few changes to the structure: - The cylinder head, valve seats, valve and combustion chamber are made of materials that can withstand higher temperature; - Special nozzles (injectors) spray oil on the underside of the pistons, cooling them; - Redesigned pistons; - The front end of the crankshaft is modified; - Oil cooler is located between the oil filter flange and filter; - In connection with the installation of the turbocharger has been modified exhaust system and intake system.
A warning All diesel engines are very sensitive to dirt, so when carrying out any work in the engine, take care that dirt or other foreign objects do not fall into the opening of pipelines and place their joints. It's best just to seal all fuel lines, hoses and other openings with duct tape. Disassembly of the engine described in detail in Sect. 17.3-17.10. Thus, we can consider the work that can be carried out either on the engine installed, or to be removed without at the same time describing an operation of disassembling the engine twice. If it is a complete disassembly of the engine, it should simply combine certain operations with each other in this order. When disassembling should mark the location of all removable parts and components to the assembly set to their original position in the event that they are reused. This is especially important for the pistons, valves, caps and bearing shells. Fold the details so as not to confuse them. |
A warning Do not mark the bearings and seals scratches on the surface or punching. Many of the parts are made of light alloy, and therefore they must be handled carefully. When removing any parts need to use a hammer, then it can only be a rubber, plastic or leather-covered hammer. |
If possible, install the engine on the corresponding mounting stand. When disassembling the motor, proceed as follows: - Remove the bracket of the thrust bearing of the drive shaft and the turbocharger; - Drain the engine oil.
| Fig. 374. When carrying out any work on dismantling disconnect: 1 - bolts of an inlet pipe; 2 - an air hose from the turbocharger; 3 - a hose from the charge air intake system; 4 - crankcase ventilation hose
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The following parts of the engine, remove the guided figure. 374: - Unscrew bolts 1 and remove the intake pipe from the turbocharger; - Disconnect the air hose 2 from turbocharger and charge air radiator; - Disconnect the hose from the charge air intake system 3; - Disconnect the hose from the crankcase ventilation 4 oil filter. Disconnect coolant piping and remove coolant hose from the holder and the oil cooler. Remove the hose clamp from the flywheel and remove the coolant pipe.
| Fig. 375. Remove vibration damper crankshaft pulley 1 and the power steering pump pulley 2. The power steering pump can be fixed in a stationary position with the hexagon
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Remove the front of the engine crankshaft pulley (4 bolts) and pulley power steering pump (Fig. 375).
| Fig. 376. The fastening of the generator. Bottom visible tensioner belt
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Remove the four screws on the engine mounting clamp and remove it.
| Fig. 377. Attaching the safety caps V-belt: 1 - top cover; 2 - lower cover
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Remove the top cover of the V-ribbed belt. It is fastened spring clamp 1 (Fig. 377). Remove the bottom cover. It is secured by three screws 2.
| Fig. 378. Removing the V-belt: 1 - a tension roller toothed belt; 2 - the guide roller toothed belt
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Remove ribbed belt. If you plan to re-establish the old belt, mark the direction of the V-ribbed belt, causing the colored label on its surface. Remove the nut and squeeze the tension roller 1 (Fig. 378) to the side. Remove the guide roller 2. Remove the timing belt. Remove the device for belt tension. Remove the cylinder head cover. Disconnect the crankcase ventilation hose from the lower connection and leave it on the cylinder head cover. Remove the protective caps placed over the bolts fastening the cylinder head cover, unscrew the nuts and remove the cover.
| Fig. 379. A method of fixing the camshaft gear
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Secure the camshaft pulley in a fixed position, remove it. Designed for the emphasis is shown in Fig. 379. Use puller for this operation is impossible, the mandrel can be inserted through the hole located behind the wheel of the metal wall and shoot down the pulley around. Remove the gear pump. It should be removed with a special three-pronged puller, teeth that need to be inserted into the holes on the gear pump. First unscrew the nut gear. To fix the gear stationary insert mandrel into the hole in the gear pump and hold it, resting the mandrel into the engine block. Remove the two bolts on the cylinder head and screw on the pump and remove the internal protection of V-ribbed belt. Remove the dipstick engine oil. Remove the tip of the wire and the fuel shut-off valve from the solenoid control valve injection. Remove the fuel from the high pressure fuel pump and injectors. They are attached by means of captive nuts. Remove the fuel pump. To do so, unfasten the two nuts on the one hand and the bolt and nut on the other side. Then disconnect the various cables and hoses. They are shown in Figure 380: - Disconnect plug connector 1 oil pressure switch; - Disconnect plug connector temperature sensor 2; - Remove the plug connector from the bracket sensor 3 crankshaft position; - Disconnect the electrical connector needle lift sensor 4 from the holder; - Disconnect the hose 5 from the coolant distribution chamber of the cylinder head. Remove the glow plug bus bar disconnect hoses and drain the oil. Loosen and remove the injector nozzles from the cylinder head. Remove the spark plugs. Disconnect plug connector coolant temperature sensor. Loosen the turbocharger around a hollow bolt, ring joint, the union nut on the turbocharger and remove the connection. Disconnect plug connector additional heating, remove the wiring harness on the engine and remove the connecting pipe for exhaust gas recirculation (4 screws). Remove the exhaust pipe and the turbocharger. First release banjo bolt ring joint oil pipeline, then turn off the heat shield to protect the exhaust pipe (2 screws), and then unscrew the 8 bolts of the exhaust pipe. Remove the 6 bolts of the exhaust manifold and remove it.
| Fig. 382. The procedure for loosening cylinder head bolts. When installing the cylinder head bolts are tightened in the reverse order
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Unscrew the cylinder head evenly in reverse order with respect to the order of the bolts (Fig. 382) and remove them. To loosen the bolts need a special allen key, without which it is possible to damage the inside of the hex head bolts, so that they will be impossible to turn. Remove the cylinder head gasket.
A warning Bolts are not suitable for re-use and must be replaced with new ones. |
Remove the bracket accessory and oil filter. Remove the fuel pump bracket (3 screws) and remove the oil cooler (one nut in the center). Remove the three screws at the base of the oil filter base and remove the oil filter. Remove the tension plate of the vacuum pump and remove the pump. Remove the components that are installed on the left side of the engine: Connect the crankcase ventilation (2 screws), the crankshaft position sensor (1 bolt, 1 spring clip) and dipstick engine oil. Secure crankshaft in a fixed position by inserting a screwdriver into the ring gear. Remove crosswise coupling bolts 6 so that they can be removed. After that, lift the clutch. Remove the front of the engine crankshaft gears and intermediate shafts. Secure crankshaft and intermediate shaft in a fixed position. Lock in a fixed position the flywheel and unscrew 6 bolts of its fastening. Remove the intermediate plate of the motor. Turn the engine and remove the oil sump (20 bolts). Remove the gasket. Remove the oil pump located at the bottom of the crankcase and remove it. Remove the six screws and remove the rear flange sealing ring. Remove the gasket.
A warning The flange is not suitable for reuse and must be replaced. |
Remove from the front of the engine crankshaft oil seal flange. Remove the gasket. Knock out the oil seal. Remove the intermediate shaft flange and push the flange. Under the flange is a sealing ring. Remove the shaft from the engine. Rotate the crankshaft so that the two connecting rods are at bottom dead center. Mark the connecting rod bearing caps, putting them number of cylinders (color) and in turn loosen the bearing caps. Remove turns together with the piston rods upwardly from the cylinder bore. Please note that the bearing shells and the bearing caps are attached directly to the respective rods. Remove the crankshaft. Bearing caps in this case are labeled (?�� 1 - from the pulleys, ?�� 5 - at the flywheel). See sub-section 17.9.
| Fig. 383. Flywheel: 1 - ring gear; 2 - bolts toothed rim; 3 - the set screw (should extend to a distance of a)
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Remove the ring gear for detecting the speed of the crankshaft, the crankshaft with a sock. In Fig. 383 shows a method of fixing it. Remove the bottom of the crankcase oil injection nozzles (unscrew the screws).
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