Engine Disassembling and Assembling

Engine, disassembling and assembling





Note:
^ If during repairs, metal shavings or quantities of small metal particles are found in the engine oil - caused, for example, by partial seizure of the crankshaft and conrod bearings - then, besides thoroughly cleaning out the oil passages, also replace the oil cooler.
^ Faulty injectors can cause violent knocking noises in the engine which sound like faulty bearings. When this occurs, run engine at idle and slacken off the injector line unions one after the other. If the knocking stops when a specific union is loosened, this is an indication that the respective injector is faulty.

Fuel injectors, servicing, Refer to Powertrain Management





Part I
1. Ribbed belt
^ Mark direction of engine rotation before removing
^ Removing and installing, Refer to Drive Belt Tensioner, Service and Repair
^ Vehicles with A/C with additional idler pulley, removing and installing: go to Fig. 5
2. 10 Nm (7 ft. lbs.) plus additional 1/4 turn (90°)
3. Belt pulley/vibration damper
^ Can only be installed in one position; holes are off-set
4. 25 Nm (18 ft. lbs.)
5. Tensioning element
^ For V-belt
^ Turn with open-end wrench to loosen ribbed belt, Refer to Drive Belt Tensioner, Service and Repair
6. Generator
7. Assembly bracket
^ for injection pump, Generator and power steering pump
^ for vehicles with A/C
^ Assembly bracket for vehicles with A/C, removing and installing:
8. 45 Nm (33 ft. lbs.)
9. Banjo bolt
^ 30 Nm (22ft. lbs.)
10. Seal
^ Always replace
11. Pressure accumulator
12. Flange
13. Pulley
^ For Engine Coolant pump





Fig. 5 Pulley, removing and installing
Only for vehicles with A/C

Removing
- Remove sound dampener tray
- Remove ribbed belt, Refer to Drive Belt, Service and Repair
- Pry off cover -1- using screwdriver.
- Remove mounting bolts -2- and remove pulley -3-.

Installing
- Position pulley -3- and tighten mounting bolt
^ Tightening torque 25 Nm (18 ft. lbs.)
- Install ribbed belt, Refer to Drive Belt, Service and Repair
- Install sound dampener tray.





Part II
1. 120 Nm (88 ft. lbs.) plus additional 1/4 turn (90°)
^ Always replace
^ To loosen and tighten, counter-hold with 3099
^ Threads and shoulder must be free of oil and grease
^ The additional quarter turn can be obtained in several stages.
2. 40 Nm (30 ft. lbs.) plus additional 1/4 turn (90°)
^ Always replace
3. 15 Nm (11 ft. lbs.)
4. 22 Nm (16 ft. lbs.)
5. Toothed belt guard, lower section
6. 10 Nm (7 ft. lbs.)
7. Toothed belt guard
8. 45 Nm (33 ft. lbs.)
9. Right engine bracket
10. Toothed belt guard, upper section
11. Toothed belt
^ Mark engine direction of rotation before removing
^ Check for wear
^ Do not kink
^ Removing, installing and tensioning, Refer to Timing Belt, Service and Repair
12. Idler wheel
13. 20 Nm (15 ft. lbs.) plus additional 1/4 turn (90°)
^ Always replace
14. 20 Nm (15 ft. lbs.)
15. 20 Nm (15 ft. lbs.)
16. 45 Nm (33 ft. lbs.)
17. Camshaft sprocket
^ Drive camshaft off of taper using hammer and drift through toothed belt guard openings
^ to loosen and tighten bolt (item 16 ), counterhold using 3036
18. Tensioning roller
^ Semi-automatic toothed belt tensioning roller, checking, Refer to Timing Belt Tensioner, Testing and Inspection
19. Idler wheel
20. Injection pump sprocket
^ Two piece construction
21. 30 Nm (22 ft. lbs.)
22. Toothed belt guard, rear
23. Coolant pump
^ Removing and installing, Refer to Water Pump, Service and Repair
24. Idler wheel
^ First remove, to remove coolant pump
^ Removing and installing, Refer to Water Pump, Service and Repair
25. Crankshaft toothed belt sprocket
26. Bushing
27. Diesel injection pump
28. Assembly bracket
29. 45 Nm (33 ft. lbs.)