6A-2 ENGINE REPAIR
ENGINE REPAIR ON WORK BENCH .................................................................................................................... 6A-84
- Prepare of engine to put it on work bench .......................................................................................... 6A-84
- Engine removal ...................................................................................................................................... 6A-85
• External components removal ......................................................................................................... 6A-87
• Timing and cylinder head removal ................................................................................................... 6A-87
• Cylinders block removal .................................................................................................................. 6A-88
- Cylinders block repair ............................................................................................................................ 6A-92
• Cylinders block measurement and revision ..................................................................................... 6A-92
• Cylinders relining ............................................................................................................................ 6A-94
• Surface finishing of cylinders .......................................................................................................... 6A-97
- Crankshaft repair .................................................................................................................................... 6A-98
• Crankshaft measurement and revision ............................................................................................ 6A-98
• Mechanical rectifying of the crankshaft bearing ............................................................................... 6A-99
• Timing driver gear replacement ..................................................................................................... 6A-102
- Checking and forming assemblies of pistons, segments and connecting roods ............................ 6A-103
• Piston and connecting rod assembly removal ............................................................................... 6A-103
• Pistons and piston rings check..................................................................................................... 6A-104
• Connecting rods check ................................................................................................................. 6A-107
• Piston and connecting rod assembly rearrangement ...................................................................... 6A-110
- Removal and repair of cylinder head ................................................................................................. 6A-112
• Removal and checking of camshaft ................................................................................................ 6A-112
• Removal and checking of plungers ................................................................................................. 6A-114
• Removal of valves .......................................................................................................................... 6A-115
• Cylinder head proof control ............................................................................................................ 6A-116
• Flatness of support surface of cylinder head control ...................................................................... 6A-116
• Cleaning valves, check and reboring seats ..................................................................................... 6A-116
• Valves guides substitution ............................................................................................................. 6A-119
• Valves seats substitution and mechanical rectifying ..................................................................... 6A-120
• Mechanical rectifying injectors seats ............................................................................................ 6A-121
• Valves springs check .................................................................................................................... 6A-121
- Installation and adjustments of cylinder head................................................................................... 6A-123
• Rear head installation ................................................................................................................... 6A-123
• Vvalves assembly installation ....................................................................................................... 6A-123
• Injector protruding, valves head thickness and valveS impermeability control ................................ 6A-123
• Valves installation ......................................................................................................................... 6A-125
• Camshaft and front oil-seal installation.......................................................................................... 6A-125
• Check and adjustment of valves play ............................................................................................ 6A-126
- Installation and adjustments of the engine ........................................................................................ 6A-127
• Installation and adjustments of cylinders block ............................................................................. 6A-127
• Cylinder head and rock arm head installation ................................................................................ 6A-136
• Timing and front part components installation ............................................................................... 6A-138
• Installation and setting of injecting pump and injectors installation
(MECHANICAL INJECTION ENGINE) (MECHANICAL INJECTION ENGINE)
(MECHANICAL INJECTION ENGINE) (MECHANICAL INJECTION ENGINE)
(MECHANICAL INJECTION ENGINE) ......................................................................... 6A-141
• Electroinjectors, hydraulic accumulator (Rail) and high pressure pump installation
(COMMON RAIL ENGINE) (COMMON RAIL ENGINE)
(COMMON RAIL ENGINE) (COMMON RAIL ENGINE)
(COMMON RAIL ENGINE) ............................................................................................... 6A-142
• Timing upper head, crankshaft pulley and electromagnetic gasket installation .............................. 6A-143
• External components over the work bench installation .................................................................. 6A-145
• External components out from work bench installation ................................................................. 6A-147
TIGHTENING TORQUE SPECIFICATIONS ........................................................................................................ 6A-148
REQUIRED SERVICE MATERIALS .................................................................................................................... 6A-153
SPECIAL TOOL ................................................................................................................................................. 6A-154
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