Note: Do not measure cylinder bore while the engine is mounted on this type of stand.
If the stand is not available, you can disassemble the engine on a sturdy workbench or on the floor. Be extremely careful not to tip or drop the engine when working without the stand.
Before disassembling the engine or replacing it with a rebuilt unit, remove all external components:
- a) Generator (together with brackets) and starter (Section 4A).
- b) Glow plugs/preheating system components (Section 4B).
- c) All components of the fuel system, including the high-pressure fuel pump, sensors and actuators (Section FOR).
- d) Vacuum pump (Section 9).
- e) All electrical switches, actuators and sensors, as well as the wiring harness leading to the engine (Section 3A, Section 4B).
- J) Inlet and outlet manifolds and, where fitted, turbogenerator (Sections FOR, 3B).
- g) Dipstick and tube for measuring engine oil level (Section 1A).
- h) Engine mounts (Section 1A).
- i) Flywheel/drive disc (Section 1A).
- j) Clutch components (Section 5) — mechanical transmission.
Note: When removing external components from the engine, pay special attention to parts that may be useful during installation. Draw the locations of gaskets, seals, pins, washers, bolts and other small parts.
If you purchased a reconditioned "short engine" for replacement (cylinder block/crankcase, crankshaft, pistons and connecting rods assembly), it is also necessary to remove the toothed drive belt together with the tensioning mechanism and covers), auxiliary belt (together with the tensioning mechanism), water pump, thermostat housing, coolant outlet elbow, oil filter housing and, where fitted, engine oil cooler.
If you are planning a complete overhaul, disassemble the engine in the following order:
- a) Intake and exhaust manifolds (see Section 3B).
- b) Toothed drive belt, sprockets and tensioning mechanism (see Section 1A).
- c) Cylinder head (see Section 1A).
- d) Flywheel/drive disk (see Section 1A).
- e) Pallet (see Section 1A).
- j) Oil pump (see Section 1A).
- g) Piston/connecting rod assemblies (see Chapter 7).
- h) Crankshaft (see Chapter 8).
The article was copied from the website: audimanual