Fix the engine on the mounting stand.
Remove the generator.
Remove starter with bracket.
Unscrew the engine mount bracket.
Drain the oil and unscrew the oil filter.
Unscrew the clutch cover from the flywheel.
Unscrew the bolts securing the flywheel. Remove flywheel.
Unscrew the bolts securing the upper and lower casings of the toothed belt leading the camshaft.
Attach tool 15-030 A (pic. 2.26).
Remove vibration damper.
Remove the gear wheel from the camshaft (pic. 2.27).
Remove the rear toothed belt cover.
Remove the gear from the injection pump shaft.
Remove the fuel pipes from the injection pump.
Unscrew from a head of the block of the engine the fuel filter with an arm.
Remove excess fuel overflow lines from injectors.
Remove the high pressure fuel lines.
Unscrew the nozzles using tool MS 1501 (Churchill).
Disconnect the electrical wires and unscrew the spark plugs.
Remove the injection pump bracket.
Remove the injection pump.
Remove the block head cover.
Remove the pipe connecting the water pump - thermostat housing.
Unscrew the thermostat housing from the engine housing.
Unscrew the block head bolts, starting from the outside and moving towards the middle. This action should be performed in reverse order. than shown in Fig. 2.28.
Remove the block head.
Remove the oil filter.
Unscrew the oil pump from the engine housing.
Remove the toothed belt wheel from the intermediate shaft.
Unscrew the intermediate shaft oil seal housing.
Unscrew the water pump.
Remove the oil pan from below the engine.
Remove the belt gear from the crankshaft (toothed belt wheel).
Unscrew the motor end plate.
After unscrewing the bolts, remove the crankshaft rear bearing cover.
Unscrew the oil suction tube together with the bracket from the engine housing.
Loosen the connecting rod bolts and remove the connecting rod bearing caps.
Remove pistons with connecting rods upwards.
Assemble bearings with connecting rods and caps. Connect with connecting rod bolts without tightening them.
Remove the crankshaft main bearing caps.
Remove the crankshaft from the engine housing.
Peel off the glued bushings and place them in their respective main bearing bores. Under no circumstances should the inserts be mixed up!
Place the bearing caps in their respective places and secure with lightly screwed bolts. Do not mix up the caps!
Degrease all parts, except for the bearings. Note: In a diesel engine, new bolts must be used at each assembly to secure the connecting rod caps and crankshaft main bearing caps.
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