Parts for disassembly and assembly of the cylinder block. 1 - oil dipstick guide and oil dipstick assembly; 2 - gasket; 3 - oil level sensor; 4 - drain plug; 5 - oil pan No. 1; 6 - front crankshaft oil seal; 7 - adjusting bracket for tensioning the drive belt; 8 - coolant pump; 9 - oil pressure sensor; 10 - generator; 11 - oil filter assembly with bracket; 12 - sealing ring; 13 - generator bracket; 14 - outlet pipe of the turbocharger lubrication system; 15 - coolant temperature sensor; 16 - flywheel; 17 - back plate; 18 - check valve; 19 - injection pump; 20 - coolant outlet pipe; 21 - thermostat; 22 - oil pump; 23 - calmer; 24 - oil receiver.
Parts for disassembly and assembly of the cylinder block. 1 - thrust half ring (bottom); 2 - crankshaft; 3 - thrust half ring (upper); 4 - the top loose leaf of the radical bearing; 5 - cylinder block; B - connecting rod cover; 7 - piston; 8 - compression ring No. 1; 9 - compression ring No. 2; 10 and 12 - oil scraper ring scrapers; 11 - oil scraper ring expander; 13 - retaining ring; 14 - piston pin; 15 - bushing of the upper head of the connecting rod; 16 - connecting rod; 17 - connecting rod bearing shells; 18 - rear crankshaft oil seal; 19 - rear seal housing; 20 - oil nozzle; 21 - lower main bearing shell; 22 - main bearing cap.
Preparation for disassembly of the cylinder block
1. (Models with manual transmission)
- A) Remove the clutch cover and clutch disc.
- b) Remove the flywheel by removing the bolts.
Note: before removing the flywheel, set marks so as not to upset the balance during installation.
2. Remove a back plate of the block of cylinders, having turned away bolts.
2. Place the engine on a stand for disassembly.
3. Remove the toothed belt and toothed pulleys of the timing drive (chapter "timing belt").
4. Remove the cylinder head, (see section "cylinder head").
5. Remove the injection pump. (see chapter "Fuel system - engines 2C, 2C-1" chapter "injection pump").
6. Remove the coolant pump. unscrewing the bolts.
7. Remove the alternator, alternator bracket and drive belt tension adjusting bracket.
8. Remove the oil level sensor.
- A) Unscrew 4 bolts and remove the sensor.
- b) Remove the gasket from the oil level sensor.
9 Remove the oil pan and oil pump.
- A) Turn away bolts and nuts of fastening of the pallet.
- 6) Insert a blade between the oil damping plate and the oil pan, cut off the sealant and remove the oil pan.
Note: Be careful not to damage the oil pan flange.
- V) Unscrew two bolts, two nuts and remove the oil receiver and gasket.
- G) Loosen the oil cooler mounting bolts.
- d) Insert a blade between the cylinder block, cut off the sealant and remove the oil separator.
Note: Be careful not to damage the oil pan flange.
- e) Remove the oil pump by removing the bolts.
9. Turn away bolts, disconnect tubes and hoses and remove an arm of the oil filter and the filter.
Final assembly
1. Turn away bolts, disconnect tubes and hoses and remove an arm of the oil filter and the filter.
2. Install the oil pump and tighten the mounting bolts.
- Tightening torque - 31 Nm
3. Install the oil separator.
- A) Remove the remnants of the old sealant; being careful not to let oil get on the contact surfaces of the cylinder block and the oil damper. Using a razor blade and a scraper, remove the old sealing material from the gasket surfaces and from the sealing grooves. Using solvent, clean both contact surfaces.
Note: Do not use a solvent that will damage painted surfaces.
- b) Apply sealant to the oil separator as shown.
Note:
- Apply a layer of sealant 5 mm thick.
- Assembly must be completed no later than five minutes after applying the sealant. Otherwise, the sealant must be removed and then reapplied.
- V) Install the oil separator, tighten the bolts evenly in several passes.
- Tightening torque - 7.4 Nm
- G) Install the oil receiver with a new gasket.
- Torque:
- nuts - 13 Nm
- bolts - 18 Nm
4. Install the oil pan.
- A) Remove the remnants of the old sealant; being careful not to allow oil to come into contact with the contact surfaces of the oil pan and oil separator.
Using a razor blade and scraper, remove the old sealing material from the contact surfaces. Using solvent, clean both contact surfaces.
Caution: Do not use solvents that damage painted surfaces.
- b) Apply sealant to the oil pan as shown.
Note:
- Apply a layer of sealant 5 mm thick.
- Assembly must be completed no later than five minutes after applying the sealant. Otherwise, the sealant must be removed and then reapplied.
- V) Install the oil pan by tightening the bolts and nuts in several passes.
- Tightening torque - 7.4 Nm
5. Install the oil level sensor
- A) Install a new gasket on the oil level sensor.
Note, install the gasket with the side shown in the illustration.
- b) Install the oil level sensor with bolts.
- Tightening torque - 5 Nm
- V) Connect the oil level sensor connector.
6. Remove the alternator, alternator bracket and drive belt tension adjusting bracket.
7. Install the coolant pump.
8. Install the injection pump. (see chapter "Fuel system - diesel engines" chapter "injection pump").
9. Install the cylinder head. (see section "cylinder head").
10. Install the timing gear pulleys (chapter "timing belt") and toothed timing belt.
11. Remove the engine from the stand for disassembly.
12. (Models with manual transmission) Install the flywheel.
- A) Apply special fixing adhesive to 2 or 3 bolt threads.
- b) Install the flywheel on the crankshaft.
- V) Install and evenly tighten the 8 bolts in several passes in the sequence shown in the figure.
- Tightening torque - 88 Nm
13. Install the clutch disc and clutch cover.