Valve clearances Examination 1. Install pushers. 2. Install the camshaft 3. Install the camshaft covers. Note. Tightening torque: 11 Nm. 4. Place the valves of the corresponding cylinder...
Compression in the cylinders — check 1. Fully warm up and then stop the engine. 2. Remove the glow plugs. 3. Disconnect the high pressure fuel pump wire connector to prevent fuel supply and test process. 4....
Engine Assembly — Device 1. Right jet thrust of the engine. 2. Right engine mounting pad. 3. Left engine mounting bracket. 4. Engine rear jet thrust bracket. 5. Rear jet thrust of the engine. 6....
Removing the engine assembly Attention. Park the vehicle on a level, hard surface. Place chocks front and rear under the rear wheels of the vehicle. Install the lifting eyes described in the spare...
Installing the engine assembly Installation is made in an order, the return to removal. Do not allow engine oil to get on the elastic elements of the engine mount. Be careful not to damage the...
Engine Assembly — Post-Installation Inspection 1. Before starting the engine, check fluid levels, including coolant and engine oil. If necessary, add appropriate liquids to the correct level. 2. Before starting the...
Installing the engine on a stand for disassembly Remove the wiring harness from the engine and drain the engine oil before installing the auxiliary holders on the engine. 1. Remove the implement drive belt. 2. Remove...
Attachment drive belt — device 1. Crankshaft pulley. 2. Air conditioning compressor. 3. Drive belt. 4. Generator. 5. Automatic drive belt tensioner.
Attachment Drive Belt — Check Attention. The described operations are performed after the engine is stopped. 1. Check the drive belt for cracks, oiling and wear. If necessary, replace the drive belt...
Attachment Drive Belt — Removal Attention. Any drive belt that has been removed from the engine must be replaced with a new one. Every time the drive belt is replaced, the auto-tensioner must be...
Attachment Drive Belt — Installation 1. Install drive belt. Attention. Make sure the drive belt is correctly installed in the pulley grooves. Check for oil or coolant on the drive belt and pulleys. Use a...
Removal and installation of an automatic tensioner Attention. Any drive belt that has been removed from the engine must be replaced with a new one. Every time the free belt is replaced, the automatic tensioner must be...
Gas distribution mechanism drive belt — device 1. Inner timing belt cover. 2. Belt drive gas transmission mechanism. 3. Camshaft pulley. 4. Threaded stud of the camshaft pulley. 5. Timing belt tensioner. 6. Cover of...
Timing belt drive — removal 1. Remove the following parts: Battery ground cable. Protective tray. Right front wheel. Right headlight assembly. 2. Remove the right side mudguard. 3. Remove the...
Timing belt drive — installation Attention. It is important to degrease the crankshaft end, crankshaft sprocket bore, and drive belt pulley bearing surfaces to prevent any slippage between the timing...
Camshaft — removal and installation Attention. Before installing, apply fresh engine oil to the parts marked in the illustration. Removing 1. Remove the following parts: Battery ground cable. Protective...
Camshaft — check after removal Camshaft runout 1. Place the Y-blocks on a perfectly flat table and lay the camshaft on them with journals No. 2 and 4. Attention. Do not interfere with the camshaft on...
Removal and installation of a cover of yokes Removing 1. Remove the engine cover. 2. Remove the air intake. 3. Remove the inlet pipe assembly and inlet hose, as well as the inlet pipe bracket. 4. Remove the...
Cylinder head — device 1. Valve lifter. 2. Valve crackers. 3. Valve plate. 4. Valve spring. 5. Cylinder head bolt. 6. Voice of the cylinder block. 7. Cylinder head gasket. 8. Lifting eye of...
Cylinder head — removal and installation Removing 1. Remove the following parts: Engine cover. Air intake pipe. rocker cover. High pressure fuel lines and fuel injectors. High pressure fuel pump. An exhaust...
Cylinder head — checks after removal 1. Deformation of the surface of the holoiki of the cylinder block. Note. When carrying out this check, it is also necessary to check the deformation of the surface of...
Cylinder head — disassembly 1. Place the cylinder head on a special dismantling stand [KV113BO200 (Mot. 1573) or equivalent]. Attention. Observe the rules of cleanliness when working with the...
Cylinder Head — Assembly 1. Install new valves and lap them into their respective seats. Thoroughly clean all parts, marking them for identification. Using a special tool (KV113B0180 (Mot....
Cylinder head — checks after disassembly 1. Measure the following valve parameters: Valve stem diameter (d). Valve face angle (A). Valve head diameter (D). Valve length (L). Valve head collar thickness (T). 2....
Cylinder head — cleaning It is very important not to scratch the gasket mounting surfaces of any aluminum parts. Using a suitable tool, remove the remnants of the old gasket from the metal...
Piston protrusion check 1. Clean the piston crown. 2. Rotate the crankshaft one revolution in the working direction to set the piston of the first cylinder to the top dead center position. 3....
Checking the axial play of the crankshaft Axial play of the crankshaft 1. Install the crankshaft. 2. Check the crankshaft backlash with a dial gauge. Axial play of the lower head of the connecting rod 1. Install...
Checking the piston diameter Measure piston diameter (A). Note. Piston diameter (A) measured at height (A) = 56 mm from the piston crown.
Piston ring clearance check Piston ring side clearance Measure backlash between piston ring and piston groove using a set of flat feeler gauges (A). If the measured value exceeds the limit value,...
Checking the diameters of the crankshaft journals Crankshaft journal diameter Using a micrometer, measure the diameter of the crankshaft main journal. Diameter of the connecting rod journal of the crankshaft Using a...
Vacuum pump — device 1. Vacuum pump. 2. Gasket. Note. : replace the part with a new one after each removal. The white arrow points to the front of the engine.
Vacuum pump — removal and installation Removing 1. Remove the engine cover. 2. Remove the battery. 3. Remove the electronic throttle control actuator. 4. Disconnect the vacuum hose from the vacuum pump side....
Vacuum pump — check before installation 1. Disconnect the vacuum hose and connect the vacuum gauge through the triple adapter. 2. Start the engine and measure the amount of vacuum produced at idle speed....
Piston size groups — service data 1. The mark for setting the piston to the correct position is directed to the side of the flywheel. 2. Distance from piston pin to piston crown (see table below). 3....
Tightening torque for threaded connections Top of the engine Note. *1 : see the tightening procedure in the text of the manual. Bottom of engine Note. *1 : see the tightening procedure in the text of the manual.