Note: Do not measure the cylinder diameter while the engine is mounted on this type of frame.
If the bed is not available, you can disassemble the engine on a sturdy workbench or on the floor. Be extremely careful not to overturn or drop the engine when working without a stand.
Before disassembling the engine or replacing it with an already rebuilt unit, remove all external components:
- a) Generator (along with brackets) and starter (Section 4A).
- b) Glow Plugs/Glower Components (Section 4B).
- c) All fuel system components including high pressure fuel pump, sensors and actuators (Section FOR).
- d) Vacuum pump (Section 9).
- e) All electrical switches, actuators and sensors, and wiring harness to engine (Section 3A, Section 4B).
- J) Intake and exhaust manifolds and, where equipped, turbogenerator (Sections BEHIND, 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. Sketch the location of gaskets, seals, pins, washers, bolts, and other small details.
If you purchased a remanufactured replacement «short motor» (cylinder block/crankcase, crankshaft, pistons and connecting rods assy), it is also necessary to remove the toothed drive belt together with the tensioner and covers), auxiliary belt (along with tension mechanism), water pump, thermostat housing, coolant outlet elbow, oil filter housing and, where equipped, 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 tensioner (see Section 1A).
- c) cylinder head (see Section 1A).
- d) Flywheel/Drive Disc (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).
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