Engine cylinder block
1 – engine cylinder block; 2 – back cover; 3 – sealing ring; 4 – oil drain plug; 5 – oil pan gasket; 6 – oil pan; 7 – plug of the technological hole of the cylinder block; 8 – oil channel plug; 9 – drain plug for coolant from the cylinder block; 10 – plug closing the hole for installing the crankshaft at TDC
Removing the high pressure fuel pump drive gears
1 – fuel pump gear; 2 – intermediate gear; 3 – crankshaft gear
1. Drain the oil from the engine.
2. Remove the exhaust manifold.
3. Remove the generator.
4. Block the crankshaft and unscrew the crankshaft pulley mounting bolt.
5. Remove the pulley from the crankshaft.
6. Unscrew the fuel lines from the high pressure fuel pump.
7. Remove the heat shield.
8. Unscrew the current busbar from the glow plugs and remove the glow plugs.
9. Unscrew the oil level gauge holder and remove the thermostat housing.
10. Remove the vacuum pump together with the oil return hose.
11. Remove the timing belt cover.
12. Turn the crankshaft to the TDC position of cylinder 1.
13. Remove the drive part and the clutch disc.
14. Remove the flywheel from the crankshaft.
15. Unscrew the camshaft pulley.
16. Remove the belt tensioner and timing belt.
17. Remove the camshaft pulley.
18. Remove the inner timing belt cover.
19. Remove the cylinder head.
20. Remove the coolant pump.
21. Unscrew the fuel pump drive cover.
22. Unscrew the gear from the high pressure fuel pump.
23. Remove the intermediate gear together with the bearing sleeve.
24. Remove the gear from the crankshaft.
25. Remove the oil pan.
26. Unscrew the oil receiver.
27. Unscrew the high pressure fuel pump drive housing from the engine cylinder block.
28. Remove the oil pump from the crankcase.
29. Remove the rear crankshaft cover.
30. Mark and remove the connecting rod caps.
31. After marking the connecting rods, remove them upwards together with the pistons from the engine cylinder block.
32. Mark and remove the main bearing caps.
33. Remove the crankshaft.
34. Remove and mark the main bearing shells and crankshaft thrust washers.
Differences when disassembling an engine with a working volume of 1.8 dm³
After removing the flywheel, remove the vibration damper. Since the high-pressure fuel pump is driven by a separate toothed belt from the crankshaft, when disassembling, it is necessary to remove the lower protective cover of the toothed belt, the toothed belt, the pulley from the pump and the high-pressure fuel pump.