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:
Removing
- a) Generator and brackets.
- b) Distributor (where applicable), high voltage wires and spark plugs (see Chapters Maintenance).
- With) Thermostat and cover (contact the head Cooling, heating system).
- d) Fuel injection equipment.
- e) Inlet pipeline and exhaust manifold.
- f) Oil filter.
- g) Engine Mounts, Lifting Eyes and Hose Mounting Brackets (refer to accompanying illustration).
- h) Auxiliary brackets (power steering pump, air conditioning compressor (refer to accompanying illustration).
- i) On the K7M engine, remove the bolt.
- j) Oil filler pipe and dipstick (refer to illustrations).
- k) Remove the sealing ring.
- l) Pipes and hoses of the cooling system (refer to illustrations).
- m) Flywheel/Drive Disc.
Diesel models
Removing
- a) Generator bracket.
- b) High pressure fuel pump and its bracket, fuel injectors and glow plugs.
- With) Thermostat and cover (contact the head Cooling, heating system).
- d) Turbocharger (where applicable - refer to Chapter Power and exhaust systems).
- e) Inlet pipeline and exhaust manifold (contact the head Power and exhaust systems).
- f) Oil cooler.
- g) Engine mounts, lifting eyes and hose brackets.
- h) Auxiliary brackets (power steering pump, air conditioning compressor).
- i) Oil pressure warning light switch and oil level sensor (where applicable) (Contact the Head Engine electrical equipment).
- j) Coolant temperature sensors (contact the head Cooling, heating system).
- k) Wiring harnesses and their brackets.
- l) Pipes and hoses of the cooling system (contact the head Cooling, heating system).
- m) Oil filler pipe and dipstick.
- n) Clutch (contact the head Clutch).
Note. When removing external components from the engine, pay special attention to parts that may be useful or important during installation. Note the correct location of gaskets, seals, spacers, pins, washers, bolts and other small components.
If purchased for replacement "incomplete" engine (those. assembly of cylinder block, crankshaft, pistons and connecting rods), it is necessary to remove the cylinder head, sump, oil pump and timing belt from the old engine.
If you are planning a complete overhaul, the engine can be disassembled and the internal components removed in the following order:
- a) Inlet pipeline and exhaust manifold.
- b) Toothed drive belt and pulleys, and water pump (refer to accompanying illustration).
- With) cylinder head (refer to accompanying illustration).
- d) Flywheel/Drive Disc.
- e) Pallet.
- f) Oil pump.
- g) Pistons.
- h) Crankshaft.
Before starting work, make sure that you have all the necessary tools at hand.