Diesel engine specifications Cylinder head The maximum flatness of the mating surface is 0.03 mm Cylinder head height: XUD series motors - 157.4...157.7 mm DW series motors: Engines 1.9 l (from the center of the camshaft to the mating surface of...
General information This chapter includes detailed information on removing the engine/transmission assembly from the vehicle, as well as information on overhauling the cylinder head, engine block/crankcase, and other internal engine...
Engine overhaul — general information It is not always easy to determine when an engine needs an overhaul. It depends on many factors. A high mileage does not necessarily indicate the need for a major overhaul. At the same time, low mileage does not at all...
Engine Removal — Technique and Precautions If you decide that the engine should be removed for an overhaul or just a major overhaul, you need to perform some preliminary operations. It is extremely important to choose a suitable place to perform such work. An...
Engine / transmission — removal and installation Note. Due to the complexity of the powertrain on these vehicles and the different situations you may encounter during operation depending on the model and optional equipment installed, the following description should...
Cylinder head (engines 2.0 l) — removal and installation Note. Due to limited access, it is not possible to remove the cylinder head while the engine is on the vehicle unless extensive additional disassembly is first performed (e.g. remove the front subframe and related...
Engine Overhaul — Disassembly Sequence 1. It is much easier to disassemble the engine and work with it if it is installed on a mobile engine assembly / disassembly stand. Often such a stand can be taken at a tool rental point. Before fixing on the stand, the...
Cylinder head — disassembly Note! New and remanufactured cylinder heads are available from both the manufacturer and engine overhaul/rebuilders. You should be aware that some special tools are required for disassembly and inspection and new items...
Cylinder head and valves — cleaning and inspection 1. A thorough cleaning of the cylinder head and valve components followed by a detailed inspection will give you the opportunity to decide what to do with the valves during the engine overhaul. Note. If the engine has...
Cylinder head — assembly 1. Lubricate the valve stems and insert the valves into the guide bushings according to the original position (pic. 9.1). If new valves are being installed, install them according to their lapping order. Pic. 9.1....
Pistons assembled with connecting rods — removal 1. Remove the cylinder head, oil pan and oil pump (see chapter 2B , 2B or paragraph 5 this chapter (whichever is applicable). 2. If there is a visible wear ridge on the top of any cylinder, it may be necessary to remove...
Crankshaft — removal 1. Remove the crankshaft sprocket and oil pump as described in chapter 2B or 2C (whichever is applicable). 2. Remove pistons and connecting rods as described in paragraph 10 . If no work is to be done on the pistons and...
Cylinder Block/Crankcase — Clean and Inspect Cleaning 1. Remove from the block of cylinders all external elements and electric switches/sensors. Ideally, for a complete cleaning, remove and smooth (rod) plugs (pic. 12.1). Drill a small hole in the removable plug...
Piston assembly with connecting rod — inspection 1. Before inspecting the piston assembly with the connecting rod, clean it and remove the piston rings from it. 2. Gently pry the rings out of the grooves. Use two or three old feeler gauges to prevent the rings from...
Crankshaft — inspection Axial clearance check 1. If you want to check the crankshaft end play, this should be done while the crankshaft is still in the cylinder block/crankcase, but it can be moved ( see paragraph 11 ). 2. Check up an axial...
Main and connecting rod bearings — inspection 1. Although the main and connecting rod bearing shells must be replaced during an engine overhaul, «old» The liners should be saved for the most careful examination, as they can provide valuable information about the...
Engine Overhaul — Assembly Sequence 1. Before assembly, check that all new parts and necessary tools are available. Review the entire procedure to assess the nature of the work to be done and ensure that everything needed to assemble the engine is at...
Piston rings — installation 1. Before installing new piston rings, check the gaps in the locks, proceeding as follows. 2. Lay out piston assemblies with connecting rods and new sets of piston rings in such a way that both when measuring gaps in...
Crankshaft — Installation Selection of bearing shells 1. Have the crankshaft inspected and measured by an engine overhauler. Specialists will be able to perform any regrinding / repair and select the appropriate liners for main and connecting...
Piston assembly with connecting rod — installation Note. At installation it is necessary to use new nuts/bolts of lower heads of connecting rods. 1. Keep in mind that the following procedure is based on the premise that the crankshaft and main bearing caps are installed...
Engine — first start after repair 1. After installing the engine on the vehicle, check the engine oil and coolant levels again (see « Weekly checks »). Check one last time that you have installed and connected everything and that there are no tools or...