Disassembling and Assembling
ENGINE, DISASSEMBLING AND ASSEMBLING
Notes:
^ If during repairs, you find metal shavings or large quantities of metal particles in the engine oil (caused, for example by partial seizure of the crankshaft and Connecting Rod bearings), then besides thoroughly cleaning out the oil passages, you must also replace the oil cooler
^ Faulty injectors can cause violent engine knocking noises which sound like damaged bearings. If this occurs, run engine at idle and loosen injector line connections one after the other. If knocking stops once the connector is loosened, this indicates that the associated fuel injector is faulty
^ Fuel injectors, servicing refer to Powertrain Management.
PART I
1. Spreader clip
2. Toothed belt guard - upper section
3. Toothed belt
- Mark engine direction of rotation before removing
- Check for wear
- Do not kink
Removing, installing, tensioning
4. 20 Nm (15 ft. lbs.)
5. Eccentric
^ for tensioning roller
6. Tensioning roller
^ Checking
7. 45 Nm (33 ft. lbs.)
8. Camshaft sprocket
- Drive off camshaft taper using hammer and drift through toothed belt guard openings
9. 25 Nm (18 ft. lbs.)
10. idler pulley
11. 10 Nm (7 ft. lbs.)
12. Toothed belt guard, rear
13. Diesel Injection pump
14. Bracket
15. Console
16. Injection pump sprocket
^ Two piece
17. Intermediate shaft sprocket
18. Crankshaft sprocket
19. 90 Nm (66 ft. lbs.) + 1/4 turn (90°) further
- Loosen and tighten using 3099 Counter-hold
- Replace
^ Threads and shoulder must be free of oil and grease
^ The additional quarter turn can be achieved in more than one step.
20. 20 Nm (15 ft. lbs.) + 1/4 turn (90°) further
- Replace
21. Toothed belt guard - lower section
22. Belt pulley/vibration damper
^ Can only be installed in one position, holes are off-set
PART II
1. Cylinder head cover
2. Cap
- Replace seal if damaged
3. Upper sealing washer
4. Cupped washer
5. 10 Nm (7 ft. lbs.)
6. Cap
7. to intake hose
8. Retaining clip
9. Positive Crankcase Ventilation valve
^ for crankcase breather
10. Gasket
- Replace if damaged
11. Valve cover gasket
- Replace if damaged
12. Breather
^ for Positive Crankcase Ventilation valve
13. Cylinder head bolt
- Note loosening and tightening sequence
14. Mounting clip
15. 0-ring
- Replace
16. Lower sealing cone
17. Fuel injector lines
- Tighten to 25 Nm (18 ft. lbs.)
- Remove using 3035 tool
- Always remove fuel line cluster as an assembly
- Do not bend or alter shape
18. Cylinder head
^ Removing and installing
- If replaced; replace entire coolant
19. Cylinder head gasket
- Replace
- Note marking
- If replaced; replace entire coolant
20. 20 Nm (15 ft. lbs.)
21. Lifting eye
PART III
1. Cylinder block
^ Sealing flange and flywheel/drive plate, removing and installing
^ Crankshaft, removing/installing
^ Pistons and connecting Rods, disassembling and assembling
2. O-ring
- Replace if damaged
3. 20 Nm (15 ft. lbs.) + 1/4 turn (90°) further
- Replace
4. Exhauster
5. Clamp
6. 20 Nm (15 ft. lbs.)
7. Connection
^ for Positive Crankcase Ventilation valve breather
8. Gasket
- Replace
9. Banjo bolt
^ 25 Nm (18 ft. lbs.)
10. to Turbocharger
11. Sealing ring
- Replace
12. 25 Nm (18 ft. lbs.)
13. Oil filter bracket
14. Oil cooler
- Coat flange contact area, outside the seal, with AMV 188 100 02
- Ensure clearance to adjacent components See note above.
15. Oil filter
- Loosen with strap wrench
- Tighten by hand
- Note instructions on filter when installing
16. 10 Nm (7 ft. lbs.)
17. Engine Speed sensor
18. Hammer head bolt
19. Coolant pump
^ Disassembling and assembling
20. Oil pan
- Clean sealing surface before installing
21. 20 Nm (15 ft. lbs.)
- Remove and install both rear bolts (transmission end) using 3185 flexible wrench
22. Gasket
- Replace
- Before installing oil pan gasket, coat oil pan flange/cylinder block flange with "D2"
23. Woodruff key
- Ensure tight fit