2. Loosen the flywheel/drive plate bolts. Temporarily insert a bolt into the cylinder block and block the flywheel with a screwdriver, or make a holding tool, as shown in photo 25.79D.
3. Remove the flywheel/drive plate from the crankshaft (photo).
4. Remove the intermediate plate from the pins on the back of the cylinder block (photo). Note the location of the wiring harness.
5. If necessary, remove the pins from the block (photo).
6. Loosen the nuts, remove the fuel container and hanger from the valve cover (where equipped).
7. Unscrew and remove the oil filter.
8. Unscrew the oil filter housing from the block, remove the gasket (photo).
9. Turn off an output branch pipe from a head of the block of cylinders. Remove the rubber O-ring from the base of the elbow (photo).
10. Turn off an output casing from a back part of a head of the block of cylinders. Remove the rubber o-ring from the casing base (photo).
11. Turn off bolts, remove a pulley from the water pump.
12. Turn off a nut, remove a special bolt fixing the bottom cover of a drive to assembly of the water pump.
13. Turn off assemblage of the water pump from the block of cylinders, remove ring consolidation.
14. Release the staples, and (where used) unscrew the nut, then remove the top drive cover (photo).
15. Unscrew the nuts, remove the rear upper cover of the timing belt from the valve cover (photo).
16. Loosen the remaining valve cover nuts, marking the location of the wiring harness and ground clamp (photo).
17. Remove reinforcement strips lift valve cover (photo).
18. Remove the oil deflector (photo).
19. Remove the gasket from the racks on the cylinder head (photo).
20. Remove the semi-circular gasket from the groove in the front camshaft bearing cap. Also remove the rubber plug on the back of the cylinder head (photo).
21. Mark the position of the drive belt pulley and crankshaft sprocket relative to each other, then unscrew the bolts securing the drive belt pulley to the crankshaft sprocket. Remove pulley (photo).
22. Turn off bolts, remove the bottom covering of a gear belt of a drive. One of the bolts will require a socket wrench. Remove the special gasket from the top of the cover (photo).
23. Rotate the crankshaft clockwise until the mark on the back of the camshaft sprocket aligns with the top of the cylinder head on the left side.
24. Loosen the nut and turn the tensioner hub counterclockwise to release tension on the timing belt.
25. Mark the direction of rotation of the timing belt with an arrow, then remove it from the tensioner, camshaft sprocket, intermediate shaft sprocket and crankshaft sprocket (photo).
26. Unscrew the nut, remove the washer and remove the tensioner wheel and collar from the rack on the front side of the cylinder head (photo).
27. Remove the bolt securing the sprocket to the camshaft. A tool can be used to lock the sprocket, as shown in photo 25.53, and this should be preferable to installing a tool through the hole in the sprocket. The latter method may damage the top surface of the cylinder head.
28. Remove the bolt and washer, remove the sprocket from the camshaft. Remove segment key (photo).
29. Use a screwdriver to pry out the front camshaft oil seal (photo).
30. Mark the position of the camshaft bearing caps, then loosen the nuts evenly and remove the caps (photo).
31. Lift the camshaft off the cylinder head (photo).
32. Prepare a box in advance with internal compartments marked by cylinder numbers.
33. Raise hydraulic tappets (photo). Place the tappets upside down in the box, preventing oil from escaping.
34. Loosen the bolt securing the sprocket to the intermediate shaft by blocking the sprocket with the tool shown in photo 25.46.
35. Remove the bolt and sprocket from the intermediate shaft. Remove the segment key (photo).
36. Unscrew and remove the back cover of the toothed drive belt (photo).
37. Unscrew the front engine lifting eye from the cylinder head (photo).
38. Turn off bolts of fastening of a head of the block of cylinders on one turn in an order, the return shown on Fig. 1.2.
39. Remove the cylinder head bolts together with their washers (photo).
40. After removing the bolts, lift the cylinder head off the block (photo). If it's stuck, hit it with a wooden mallet. Do not insert the lever into the gasket connection.
41. Remove the cylinder head gasket from the block (photo).
42. Unscrew and remove the generator mounting bracket (photo).
43. Unscrew the suspension of the engine mount bracket on the left side of the block (photo).
44. Unscrew the engine mount bracket hanger and rod on the right side of the block using a socket wrench (photo).
45. Remove the two bolts from the intermediate shaft seal flange. Remove flange, O-ring and stuffing box (photo).
46. Remove the intermediate shaft from the block (photo).
47. Temporarily insert two flywheel/drive plate bolts at the rear of the crankshaft and block the crankshaft with a long rod. Loosen the crankshaft sprocket bolt (strongly clamped), and remove the sprocket from the crankshaft (photo).
48. Grasp the dipstick tube with a pair of grips and carefully pull it out of the hole in the block (photo).
49. Turn over the engine, then unscrew and remove the pan bolts.
50. Remove pan and gasket (photo).
51. Unscrew and remove the covers of the front and rear crankshaft oil seals, remove the gaskets (photo).
52. Unscrew the bolts with a socket wrench, remove the suction pipe from the oil pump Remove the O-ring (photo).
53. Unscrew and remove the large oil pump mounting bolts, then remove the pump from the block (photo).
54. Mark with a puncher the position of each connecting rod and cap according to the cylinder number (photo).
55. Turn the crankshaft so that the No. 1 piston is at BDC, then unscrew the nuts and remove the connecting rod lower bearing cap (photo).
56. Lay the block on its side, use a hammer handle to push the connecting rod and piston through the top of the cylinder. Place the bearing cap with the connecting rod.
57. Repeat the procedure given in steps 55 and 56 for the remaining pistons and connecting rods.
58. Check that each main bearing cap is numbered (photo), starting from the front end of the engine.
59. Loosen and remove the cover bolts #1, 2, 4 and 5, then remove the covers.
60. With cover No. 3 installed, determine the side play of the crankshaft with a feeler gauge inserted between the thrust washer and the crankshaft web (photo). This will determine the wear of the thrust washers by comparing side play with the data in the Specifications.
61. Unscrew and remove the No. 3 main bearing cap.
62. Make sure each bearing shell is stored with the appropriate cap.
63. Lift the crankshaft out of the crankcase (photo).
64. Remove the bearing shells from the crankcase by stacking them in the correct order (photo).
65. The engine is now completely disassembled.
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