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‘Be... : Engine DISMANTLING AT THE BENCH ~ Sequence of dperations ~ 2000 i.e. engine - cross section = 2000 ie. engine - longitudinal section "CYLINDER BORES - CYLINDER BLOCK linder bores - ces block CRANKCASE COMPONENTS: /~ Crankshaft ~ Main bearings = Measuring main journal running clearances — Thrust washers - Fitting main bearing age ~ Crankshaft rear cover ~ Crankshaft front cover with incorporated oil pump ~ Vibration damping system with “counter shafts - Flywheel _ = Piston/conneeting rod assembly - Pistons = Gudgeon pins - Piston rings ; = Connecting rods ~ Small end bushes - Fitting piston/ connecting rod assembly ~ Big end bearings 2 = Measuring crankpin running clearances _ CYLINDER HEAD ~ Dismantling cylinder head = Valves “alve guides — Valve springs = Upper cylinder head - Camshaft ~ Tappets ~ Fitting cylinder head Adjusting valve clearances ASSEMBLY AT THE BENCH - Tightening cylinder head, ~ Refitting various comporients ~ 2000 i.e. turbo engine - cross section ~ 2000 ite. turbo engine - longitudinal section TIMING GEAR ~ Refitting timing gear omponents — Adjusting valve timing = Adjusting timing belt tension 41 = Positioning TDC and rpm sensor mounting plate 42. 43 47 48 52 33 54 55 56 59. 0 61 oa BRE "COMPLETION AT THE BENCH a eee eee Adjusting tension of counter shaft double- sided toothed belt = Completion of assembly " FUEL SYSTEM _ = Diagram of fuel system — Removing/refitting inlet manifold COOLING SYSTEM _ = Water pump — Thermostat — Diagram of cooling system _ LUBRICATION Diagram of lubrication system = Crankshaft-driven oil pump - SPECIAL TOOLS TORQUE WRENCH SETTINGS 10. 70 a 83 87 90 92 94 96 7 Frey a the tench Se... vn )©=—t~CSsti . ° 3 Engine Dismantling atthe bench, 10. -@ oO ge EEE Sores Cynder tock ee. 10. e eo. oan Engine Be camming 10. int mr cs te align te iil pring Engine ____Grankease components 10. | Engine Grankease components a % nao EE # ee Crankeate components = Engine 10. oe.- Engine oo Grankease components eo. C ood re aa _86-. 10. 4" Leal! Engine ee. Engine —_______Golinder head eo. es.. calneing a. Assent at he Boek 10. 4 ee coxa sen Be Engine : Bea.. i ee Bogie, . Engine ‘Timing near Engine Completion at the bench Ene atte tenes HB e 10. a = Engine Conletion atthe bench 10. eo. Eee bone eo. 10. e tena swe cng this @ Engine Completion 10. at the bench Ses. Engine a iris Cooling system te mal trough oe rh ee Sy nd ete Si rade (hulu ate ond cme thio theater thar ieesing Te iinet es ieee seas ‘arms he coed pain dm Therma ve pen ptm het e- om on =o. ine E cen eo. e 10. et Spine fo water ps ie tl Sfamer (amr cama ‘Soumner free sr einer Seater a. SSE hina Eee via eng pion Seat tans seen in ce Seuoranar Soe ae 1 Beers area pean co oe ia cuman @ Bedighier SSE Pa cama: St Me [_stesias 2 Cini na [ators eta Tepid wa - j++ _| Tent ench stings ee 10. e [Siseinrnncuieiwumcmme wy Conn or AaB somnsion ang TAC yey | eee caer ee eee aa | tsng ot er moog pe [ers = _@ —— ape] “Remora oer a ome ve | Nurscang power ing Paley Minis 7 ‘Spore