Build Engine

Assembling the engine as demolition, will be described in a separate subsection. The procedure for assembling the reverse with respect to disassembly. However, at each assembly observe the following guidelines:

- Details should be clean;

- Always lubricate any rotating or moving parts. This should be done before the assembly (and not after the items have already been installed), then the oil will get all the necessary places. It is particularly important abundantly Lubricate pistons, piston rings and cylinder walls prior to assembly;

- Thoroughly clean all parts of the cylinder, if there was a complete disassembly of the engine. In partial disassembly, make sure that that the inside of the disassembled engine or in its cavity is not hit foreign objects. Plug all openings clean cloths to avoid this;

- Blow out the oil passages with compressed air. If you do not have such a possibility, the clean oil channels and holes with a wooden stick, but in no case do not do it with metal objects.

The data table for the adjustment and control of the majority given boundary wear of moving parts. If you have doubts about any part or deterioration borders will soon be reached, this item should be replaced to avoid the re-disassembly of the engine.

Next, the assembly of the engine after its complete dismantling. We proceed from the fact that all parts of the engine have been repaired or replaced in accordance with the instructions given in the following sections. Furthermore, we assume that the separate structural groups, such as the cylinder head are already assembled.

Install the oil nozzle in the engine block. Tighten the injector to 10 Nm.

Screw the ring gear speed sensor crankshaft. The bolts should always be changed for new ones. The crankshaft is inserted adjusting pin (see. Figure 383), the pin will protrude by a certain amount from the surface of the crankshaft (2.5-3.0 mm). So before you fasten the toothed rim (10 N ?� m), measure the distance over which the adjusting pin acts.

Lubricate all working surfaces of the crankshaft bearings with engine oil and place the shaft on the bearing shells attached. Carefully place the crankshaft in the bearing and install shims on the left and right of the middle of the bearing. Oil grooves shims should be placed against the bearing surface of the crankshaft.

Install the cylinder block according to the labels crankshaft bearing caps (bearing shells must be inserted and well lubricated) and obbeyte their plastic or rubber hammer.

Screw the bolt main bearing caps and tighten them uniformly from the middle to the outside to 65 Nm. From the end position, turn each bolt again from the center to the outside, even at 90 ?� (a quarter turn).

Check the axial clearance of the crankshaft, as described in Sec. 17.9.1.

Set the pistons and connecting rods (see. P. 17.5.5).

Press fit a new oil seal from the outside in the flange of the intermediate shaft.

Grease basic necks of the intermediate shaft and insert the intermediate shaft to the crankcase. Install new O-ring into the flange shaft and install flange. Tighten both bolts to 25 Nm.

Knock out the oil seal from the housing front oil seal. Insert the housing without oil seal into the cylinder block. Tighten the 4 bolts to 25 Nm. In Fig. 384 shows a method of its mounting.

Install a new front oil seal, as described in Sec. 17.9.3.

After that, screw the housing rear oil seal with a new seal. Tighten as shown in Figure 385 bolts to 10 Nm.

Connect the oil pump to the bottom of the housing (2 screws, 25 Nm). In Fig. 386 shows the locations of their mount.

Install oil sump with a new seal. Tighten the bolts in a circle to 20 Nm.

Install intermediate plate motor (3 screws, 10 Nm).

Install the flywheel. The bolts should be tightened evenly crosswise to 60 Nm. From the end position, turn all the bolts another 90 ?� (quarter turn) (without using a torque wrench).

Install the clutch, as described in the relevant section. Thus the flywheel must be locked in a fixed position.

Install the crankshaft gear. Grease the bolt. Secure crankshaft in a fixed position, preventing crank flywheel, and tighten the bolt to 90 Nm. From the end position, turn the bolt another 90 ?� (without using a torque wrench).

Put the gear of the intermediate shaft onto the shaft. The shaft has to be woodruff key. Fix the gear in a fixed position and tighten the bolt to 45 Nm.

Install the parts removed from the left side of the engine. Tighten the crankshaft position sensor to 10 N ?� m, and the compound crankcase ventilation to 25 Nm.

Set the vacuum pump with a new sealing ring (20 Nm).

Install the base of the oil filter with a new gasket (3 bolts, 25 Nm).

Screw the bracket 1 securing the high pressure pump (Fig. 387) with three screws. Tighten the bolts to 20 Nm and then tighten a further 90 ?�. Install oil cooler with new gasket. Tighten the nut at the bottom of the oil cooler 25 N ?� m.

Install the support bracket assemblies. Replace the O-ring of the cylinder. Install the bracket to the guide holes and screw the five screws. Connect the coolant hose to the oil cooler. At the same time as the oil filter screw (section 18.3). Tighten the bolts of the bearing bracket units in the sequence shown in Fig. 388, 25 N ?� m.

Measure how much are the pistons (see. P. 16.3.5) and pick up the cylinder head gasket according to the obtained value measurement.

Install the cylinder head (Sec. 16.2.5).

Install the intake manifold with a new gasket and secure it with six screws (25 Nm).

Install new gaskets exhaust pipe so that they looked rounded up, install a pipe with a turbocharger and tighten them (25 Nm). Install oil return hose, tighten the banjo bolt ring connection (30 Nm) and secure the screen thermal protection (two screws).

Connect the turbocharger oil pipeline (union nut). Tighten it to 25 Nm. Tighten the banjo bolt in the cylinder head to 25 Nm.

Screw the connecting pipe for exhaust gas recirculation (25 Nm).

Connect the plug connector of additional heating.

Install the injector with spikes. Tighten spikes to 22 Nm. In Fig. 389 shows where the nozzles are mounted.

Replace the spark plugs. Tighten them to a torque of 15 Nm (see. Fig. 389). Connect the plug connector coolant temperature sensor on the right side.

Screw the bus line glow plugs and install the oil drain hose.

Connect all wires to the sensor (see. Fig. 381). Connector strip with a blue / black wire mounted on blue oil pressure switch, plug connector with the yellow / black wire is set to gray oil pressure switch.

Set the pump (see. The relevant section).

Establish an internal toothed belt protection (2 bolts in the cylinder head, one bolt on the high pressure fuel pump).

Install the gear pump. First, put the woodruff key. Fix the gear in a fixed position and tighten the nut to 55 Nm. Screw and tension roller toothed belt without tightening it definitively.

Install poly V-belt as described in the relevant section. Fixing the camshaft gear in a fixed position, tighten the bolts to 45 Nm.

Plug conduits supplying fuel to the injection system. Tighten the union nuts to 25 Nm. Connect the plug connector located nearby.

Install the cylinder head cover. Use a new gasket. Tighten the nuts to 10 Nm and fit protective caps. Connect the breather hose. Then install the timing belt protection is now.

Screw the front collar of the engine mount. Tighten the bolts to 60 Nm.

Install the generator (25 Nm).

Put the crankshaft pulley via a dowel pin on the crankshaft timing gear and tighten the bolts. Tighten the bolts to 25 Nm. Screw the water pump pulley (23 Nm).

Screw the thrust bearing of the drive shaft (43 Nm) and the support clamp turbocharger (25 Nm).

Perform all work not mentioned specifically in the reverse order, on the process of dismantling.