Dismantling, repair and assembly of the engine

Disassembly

1. Mount the engine on a suitable frame, drain the oil and remove the oil filter. Remove the vacuum pump and drive V-belt; unscrew the vacuum line.

2. Remove the complete alternator (together with the holder) and drive V-belts, coolant pump V-belt tensioner pulley and belt.

3. Unscrew the high idle regulator thermostat from the cylinder head, then unscrew the fuel return hoses and remove the fuel pump.

4. Unscrew and remove fuel lines. Seal the openings of the pipes and fittings of the fuel system with appropriate plugs to prevent dust from entering there.

5. Remove the injectors, their gaskets and thermal insulation rings, disconnect the electrical wire and current bus from the glow plugs and unscrew them.

6. Disconnect the oil supply line to the valve lever shaft and unscrew the outer holders of the valve lever shaft.

7. Loosen the cylinder head bolts (in reverse order with respect to their tightening) and remove the head and its gasket.

8. Remove the oil filter holder and oil cooler, and then unscrew the fuel pump with its holder. Remove the crankshaft and fan pulleys, remove the casing of the timing chain.

9. Block the chain tensioner with a screwdriver, remove the device and its eccentric, remove the timing chain and the fuel pump sprocket.

10. Remove the fuel pump drive mounting flange and oil supply pipe.

11. Pull the sprocket off the crankshaft and remove the timing chain tensioner.



12. Remove the drive part and clutch disc, oil pan, oil pump plug, oil pump nut and bolt from the flywheel, and then remove the oil pump.


13. Turn the engine 180°, remove the intermediate plate from the cylinder block, remove the camshaft, and then use a puller to remove the sprocket from the camshaft.

14. Remove the tappets and install them in the sequence they occupy in the engine.

15. Identify the main bearing caps, as well as the connecting rods and their caps (from the fuel pump).

16. Remove main bearing caps and connecting rod caps.

17. Remove the crankshaft from the engine block.

18. Remove the pistons from the cylinders together with the connecting rods.

19. Install the liners together with the covers in the sequence they occupied in the engine.

Assembly

Attention! Before assembling the engine, check all parts and install only clean and in good technical condition.

Attention! Observe: the required connections of interacting parts, the correct relative position of these parts and their correct installation in accordance with their designations.

1. Replace all gaskets and spring washers to prevent loosening of bolts.

2. Clean mating surfaces of gaskets and mating parts. Do not use abrasive materials or sharp tools for cleaning. These surfaces must not show signs of impact, abrasions or scratches.

3. The oil passage holes in the engine block should be plugged with copper plugs coated with Loctite Frenetanch sealing paste.