Necessary equipment
DW 100-130 Engine overhaul stand
KM-470-B Angle Torque Indicator
EN-48251 Crankshaft rear oil seal installer
EN-48249 Piston Ring Compressor
Disassembly procedure
1. Remove the engine. follow the paragraph «Complete engine» in this section.
2. Remove the flywheel or flex plate screws.
3. Remove flywheel or flexible plate.
4. Install the engine on the engine overhaul stand DW100-130.
5. Remove the cylinder head. follow the paragraph «Cylinder head and gasket» in this section.
6. Remove the oil pan. follow the paragraph «oil pan» in this section.
7. Remove the crankshaft balancer. See «crankshaft balancer» in this section.
8. Remove the oil pump. See «Oil pump» in this section.
9. Remove the starter. See Part 1E1, Engine Electrical - 2.0 Diesel.
10. Remove the generator. See Part 1E1, Engine Electrical - 2.0 Diesel.
11. Remove the air conditioning compressor. See Section 7D, Automatic temperature control, heating, ventilation and air conditioning system.
12. Remove the A/C compressor and alternator bracket.
13. Remove the connecting rod and piston.
14. Remove the engine base plate.
15. Remove the crankshaft with the rear oil seal.
16. Remove the grease nozzle tube.
Cleaning procedure
1. Clean the sealing surface of the base plate.
2. Clean the sealing surface of the cylinder block.
3. Clean the base plate pinch bolts.
4. Clean the bolt holes in the base plate.
Assembly procedure
1. Lubricate the main bearing with engine oil.
2. Install the grease nozzle tube.
Tighten
Tighten the grease nozzle tube bolts to 23 Nm (17 lb-ft).
3. When replacing the crankshaft, the wheel with "target" for crankshaft position sensor (CPS) transfer to a new crankshaft.
Tighten
Tighten the wheel tie bolts with "target" for crankshaft position sensor (CPS) up to 12 Nm (8.9 lb-ft).
4. Install the crankshaft together with the main bearing shells.
5. Install the engine base plate. See «Engine base plate» in this section.
6. Check the end clearance of the crankshaft with main bearings installed. follow the paragraph «Engine Specifications» in this section.
7. Check the permissible axial clearance of the crankshaft. follow the paragraph «Engine Specifications» in this section.
8. Lubricate the piston and rings with engine oil.
9. Insert piston and connecting rod with EN-48249 piston ring compressor.
10. Install the connecting rod head screws.
Tighten
Tighten the big end cap bolts to 25 Nm (18.4 lb-ft). Using the KM-470-B angle torque gauge, tighten the big end cap bolts an additional 90 degrees.
11. Check the end play of the connecting rod. follow the paragraph «Engine Specifications» in this section.
12. Install a new crankshaft rear oil seal using the EN-48251 rear crankshaft oil seal installer.
13. Install the A/C compressor and alternator bracket.
Tighten
Tighten the A/C compressor and alternator bracket bolts to 35 Nm (25.8 lb-ft).
14. Install flywheel or flexible plate.
Tighten
Tighten the flywheel or flexplate pinch bolts to 105 Nm (77.4 lb-ft).