General information about diesel engine Engine Identification Data The engine is identified by the engraving (A) made on the cylinder block. Description of markings The marking indicates: (1): engine model, (2): engine certification letter, (3): engine index,...
Preparing for engine repair Note: All work on the engine must only be performed by suitably qualified personnel. When performing repair work on a vehicle, it is necessary to follow basic safety rules. The quality of repair depends primarily on the...
Compression check 1. Remove the engine pre-heating plugs. 2. Disconnect the fuel supply drive connector (3). 3. Using an open-end wrench, moderately tighten the hose tip and compression tester adapter. 4. Connect the independent starter....
Replacing the accessory drive belt Attention: Use protective gloves. Do not start the engine without the accessory drive belt installed - there is a risk of damage to the crankshaft pulley. Removal the accessory drive belt 1. Place the vehicle on a...
Removal and installation the air conditioning compressor Caution: Observe precautions when handling refrigerant (see chapter " Air conditioning system "). Note: To remove the air conditioning compressor, a special station for draining and filling the air conditioning system...
Removal and installation a vacuum pump Removal the vacuum pump 1. Remove the engine cover. 2. Disconnect the hose (1) from the brake booster. 3. Loosen the mounting bolts (2) and remove the vacuum pump. Installing a vacuum pump Installation is carried out in...
Removal and installation of the power unit assembly 1. Cylinder head mounting support. 2. Engine with gearbox assembly. 3. Front side member. 4. Front subframe of the car. 5. Rear engine mounting support. 6. Engine thrust rod. 7. Gear plug support. 8. Front side member....
Installation of the power unit Attention: Be sure to replace the gasket between the catalytic converter and the exhaust downpipe with a new one. To prevent leaks, make sure that the gasket and the contact surfaces of the pipes are in good condition....
Repair of an engine removed from a car Installing the engine on the assembly stand Attention: It is strictly forbidden to apply any pressure to the engine oil pan. Damage to the pan can also cause various damages to the engine itself due to: blocking the oil...
Preparing engine parts for assembly Parts that must be replaced with new ones: all seals, damaged cooling system hoses, drive belts, drive belt tensioners and rollers, crankshaft pulley bolt, camshaft sprocket bolt, exhaust manifold nuts, exhaust manifold...
Engine components that can be reused when replacing an engine Preparing the old engine for return to the factory for further refurbishment 1. Clean the engines. 2. Drain the engine oil and coolant. 3. Fix the old engine on the stand. 4. Install plastic plugs and caps. 5. Place the...
Removal the timing belt of the gas distribution mechanism drive Attention: Use protective gloves during work. Do not turn the engine crankshaft against the normal direction of engine rotation. Do not start the engine without the accessory drive belt installed to avoid damaging the...
Installing the timing belt of the gas distribution mechanism drive Note: Be sure to replace the timing belt, timing belt tension roller with bolt and crankshaft pulley bolt with new ones. 1. Install a new timing belt tensioner roller. 2. Insert the tab (14) of the timing belt tension...
Adjusting valve clearance Adjustment values Adjustment clearance on a cold engine, mm: For intake valves: 0.20 +0,05 -0,075 ; For exhaust valves: 0.40 +0,05 -0,075 . Note: To replace the tappets, the camshaft must be removed. Adjustment Method...
Rocker cover Attention: Use protective gloves when performing work. Removal the rocker cover 1. Place the vehicle on a two-post lift. 2. Disconnect the negative battery terminal. 3. Disconnect the connector (1) of the oil vapor...
Removal the cylinder head Attention: Before performing any work on the injection system circuit, the following must be checked using diagnostic equipment: Make sure the fuel rail is not under pressure. Make sure the fuel temperature is not too...
Disassembling the cylinder head 1. Remove the cylinder head from the engine. 2. Install the cylinder head on the disassembly stand (Mot. 1573). 3. Loosen the nuts (1) securing the fuel rail guard 4. Remove the fuel rail protection. 5. Clean the high...
Cleaning the cylinder head Attention: Do not scratch the aluminum contact surfaces, any damage to the contact surfaces may cause leaks. Use safety glasses with side protection and sealed gloves (nitrile type). Avoid contact of cleaning agent with...
Checking the valves 1. Remove the cylinder head from the engine. 2. Remove the valves from the cylinder head. 3. Before testing, clean all parts to be tested with a cleaning agent and dry with compressed air. 4. Make sure that the parts...
Checking valve springs Note: The springs for the intake and exhaust valves are identical. Valve springs must be installed with the narrowed part (6) facing upwards. 1. Remove the valve springs (see above) and position them according to their...
Cylinder head assembly 1. Clean the cylinder head, valves, valve springs, valve retainers, valve crackers and valve guides. 2. If a new cylinder head is used, install the lifting eye on the flywheel side of the cylinder head and tighten the...
Installing the cylinder head Note: Always replace the cylinder head gasket and bolts with new ones. Attention: It is necessary to use protective equipment (gloves, glasses and respirators). Thoroughly clean the cylinder head to prevent foreign...
Replacing the front camshaft oil seal Removal 1. Place the vehicle on a two-post lift. 2. Disconnect the battery. 3. Disconnect: right front wheel, right support of the pendulum suspension, accessory drive belt, timing belt. 4. Disconnect: the camshaft...
Removal and installation the camshaft Removal 1. Place the vehicle on a two-post lift. 2. Disconnect the battery. 3. Disconnect: air filter housing, right front wheel, accessory drive belt, right support of the pendulum suspension, timing belt, vacuum pump,...
Replacing the front crankshaft oil seal Removal 1. Place the vehicle on a two-post lift. 2. Disconnect the negative battery terminal. 3. Remove the front right wheel from the vehicle. 4. Remove the timing belt of the gas distribution mechanism drive. 5....
Replacing the rear crankshaft oil seal Removal the rear crankshaft oil seal 1. Place the vehicle on a two-post lift. 2. Disconnect the battery. 3. Remove the gearbox and clutch discs. 4. Remove the flywheel. 5. Install the oil seal puller (Mot. 1579) on the...
Cylinder block Disassembling the cylinder block 1. Remove the power unit assembly (engine with gearbox) from the car. 2. Disconnect the gearbox from the engine (see chapter " Transmission "). 3. Remove the accessory drive belt. 4....
Special tools and devices Name of tools and devices Catalogue number Hose Clamp Pliers Mot. 1448 Support stand for removal/installation of engine/gearbox assembly Mot. 1390 Engine support beam with multiple adjustments and rigging Mot. 1453...