2. Engine disassembling & assembling
Engine disassembling
Step 1
Remove the pipe (1) from the thermostatic valve
sat, loosen the alternator retaining bolts and
remove the fan drive belt (2).
Step 2
Remove the retaining bolts, fan (1) spacer and
drive pulley (2), detach the return pipe (3) from
the coolant pump.
Step 3
Remove the retaining bolts and detach the
coolant pump (1).
Step 4
Remove the retaining bolts and detach the
coolant pump support (1).
A1.48 MR306-10.2004-EN
3. Engine disassembling & assembling
Engine disassembling
Step 5
Unscrew the unions (2 and 3) on the injection
pump and fuel pump, remove the retaining bolts
and extract the fuel pump, complete with support
lines.
Step 6
Remove the retaining bolts and disconnect the
complete thermostatic valve unit (1).
Step 7
Remove the retaining bolts and remove the
alternator (1), complete with support (2).
Step 8
Unscrew the retaining bolts and disconnect the
exhaust manifold (1).
Step 9
Remove the engine oil filter (2).
MR306-10.2004-EN A1.49
4. Engine disassembling & assembling
Engine disassembling
Step 10
Disconnect the injection pump and injection line
(2).
Step 11
Remove the retaining bolts and remove the inlet
manifold (1).
Step 12
Make sure that there is references marks (2) for
injection pump timing operations and remove the
pump retaining bolts (1).
Step 13
Remove the access cover (1) of the injection
pump drive gearbox.
A1.50 MR306-10.2004-EN
5. Engine disassembling & assembling
Engine disassembling
Step 14
Unscrew the nut securing the injection pump to
the drive gear (1).
Step 15
Extract the injection pump drive gear-using tool
1035170097 (2) and recover the injection pump
and the woodruff key.
Step 16
Unscrew the retaining nuts (1) and recover the
fuel pump support (2).
Step 17
Disconnect the hydraulic delivery & suction pipe
(1 & 2 respectively) by loosening their Allen key
bolts and disconnect the hydraulic filters.
Step 18
Remove the retaining bolts and detach the starter
motor (1).
1
1
2
MR306-10.2004-EN A1.51
6. Engine disassembling & assembling
Engine disassembling
Step 19
Remove the injector mounting nuts, the
underlying spherical washers, then the supports
and the injectors themselves.
Step 20
20.Remove the rocker cover bolts (1), washers
and seals, and then the rocker cover (2) and its
gasket.
Step 21
Remove the rocker shaft retaining bolts (2), and
then remove the entire rocker shaft assembly (1).
Step 22
Remove the valve collets (1) and extract the
pushrods (2).
Step 23
Unscrew the cylinder head bolts (1) and remove
the head using a hoist and lifting hook.
Step 24
Remove the cylinder head gasket.
A1.52 MR306-10.2004-EN
7. Engine disassembling & assembling
Engine disassembling
Step 25
Turn the engine upside down on the rotary stand,
remove the sump pan bolts, the sump pan (1)
and its gasket (2).
Step 26
Unscrew the retaining bolts and remove the oil
pick-up pipe (1) complete with the strain filter and
seal.
Step 27
Unscrew the retaining bolts (2) and detach the
counter weight housing (3) by moving it outward,
remove the sleeve coupling (4) and the housing
(3).
Step 28
Unscrew the sump pan retaining bolts (4) and
remove the sump pan using a hoist, lifting hook
and lifting chain with eyeholes.
Step 29
Remove the half-gaskets (1) and (3) between the
crankcase and sump pan and the gasket (2)
between the timing gear carrier and sump pan.
Step 30
Remove the gasket (1) between the flywheel
carrier and sump pan.
NOTE: When relocating gaskets (1), in this figure
and (2), in previous figure, apply RHODORSIL
CAF 1 silicone sealing compound to the mating
surfaces.
MR306-10.2004-EN A1.53
8. Engine disassembling & assembling
Engine disassembling
Step 31
Remove the rotating counterweight oil seal O-ring
(1) installed on the crankcase-mating surface.
Step 32
Unscrew retaining bolts (1) and remove the
complete oil pump.
NOTE: For model 8045.25.785 refer to point 54.
Step 33
Unscrew the retaining bolts (2) and remove the
crankshaft pulley (1).
Step 34
Straighten the lock tab, hold the crankshaft
against rotation and unscrew nut.
A1.54 MR306-10.2004-EN
9. Engine disassembling & assembling
Engine disassembling
Step 35
Pull the pulley hub off the crankshaft using (1)
and recover the woodruff key.
Step 36
Unscrew the retaining bolt (1) and remove the
timing cover and its gasket.
Step 37
Unscrew the retaining bolts and remove the lift
pump gear carrier (1).
Step 38
Remove the spring ring (1) and remove the thrust
washer and the intermediate gear (2).
NOTE: When refitting the intermediate gear see
engine timing instructions.
MR306-10.2004-EN A1.55
10. Engine disassembling & assembling
Engine disassembling
Step 39
Unscrew the retaining bolts (1) and remove the
intermediate gear journal.
Step 40
Unscrew the retaining bolts (2) and withdraw the
camshaft (3) complete with the crankshaft gear
(1) and the end plate (4).
Step 41
Remove the spring ring (1) and the thrust
washer, and withdraw the gear with fuel supply
pump camshaft (2) from the opposite side.
NOTE: This gear transmits drive to the injection
pump. On re-assembly see timing instructions.
Step 42
Unscrew the retaining bolts (1) and remove the
timing gear case.
A1.56 MR306-10.2004-EN
11. Engine disassembling & assembling
Engine disassembling
Step 43
Remove the O-ring seal (1) installed in the lift
pump drive shaft lubrication line.
Step 44
Remove the crankcase - timing gear case gasket.
Step 45
Rotate the engine on the stand. Unscrew the big-
end cap bolts (2) and recover the big-end caps
with their shell bearings.
Step 46
Slide the pistons (1), complete with rings,
gudgeon pins and connecting rods, out of the
cylinder linings.
Step 47
Rotate the engine on the stand through 90 o
back
to the horizontal position. Unscrew the flywheel
bolts and remove the flywheel with the aid of a
hoist and hook.
Step 48
Unscrew the retaining bolts and remove the rear
oil seal carrier (1) complete with gasket
MR306-10.2004-EN A1.57
12. Engine disassembling & assembling
Engine disassembling
Step 49
Unscrew the main bearing cap bolts (1), and
remove the main bearing caps with relative
bearing shells, and recover the thrust washer
located on the penultimate main bearing, as
shown in the figure.
Step 50
Lift the crankshaft clear of the crankcase using a
hoist and nylon sling. Recover the bearing shells,
thrust washers and tappets.
Step 51
Turn the engine on the stand through 180 o
;
attach the lifting chain with eyeholes to the
crankcase, as shown in the figure.
Step 52
Lift the engine clear of the stand.
Step 53
Unscrew the retaining bolts and remove the rear
crankcase housing (1) and its gasket.
NOTE: Oil pump model 8045.25.785
Step 54
Remove the fixing screws (4), and take off the
washers (3) and the engine lubrication oil pump
(2) complete with pressure relief valve (1).
Step 55
Remove the lubricating oil pipe (3). as shown in
the next figure.
Step 56
Remove spring ring (18)
Step 57
Remove spring ring (25) and cover (23) with
relative O- ring seal (24).
Step 58
Withdraw gear (22) from sump.
A1.58 MR306-10.2004-EN
13. Engine disassembling & assembling
Engine disassembling
Step 59
Remove spring ring (2), gear (26) and the thrust
washers (1).
Step 60
Inspect the shaft (27). If signs of scoring or wear
are evident, the shaft must be replaced.
Step 61
Withdraw the spring pins (4) and dismantle the
counter weight shaft using a suitable drift.
Step 62
Remove the counterweight drive gear (13) by
removing the spring ring (9) and the carrier
retaining bolts (6).
Step 63
Remove spring ring (4) and intermediate gear (3).
1. Thrust washers.
2. Spring ring.
3. Lubricating oil pipe for bushing (28).
4. Shaft retaining spring pin (5).
5. Counterweight rotation shaft.
6. Counterweight.
7. Carrier for counterweight drives gear (13).
8. Thrust washer.
9. Circlip.
10. Counterweight intermediate gear.
11. Bolts securing counterweight housing to
sump.
12. Counterweight housing.
13. Counterweight drives gear.
14. Screen filter.
15. Screen filter retaining bolt
16. Bushing.
17. Rigid coupling sleeve.
18. Spring ring.
19. Thrust washer.
20. Carrier for gear (22).
21. Thrust washer.
22. Counterweight drives gear.
23. Cover.
24. O-ring seal.
25. Spring ring.
26. Intermediate gear.
27. Shaft for gear (26).
28. Bushing.
MR306-10.2004-EN A1.59
14. Engine disassembling & assembling
Engine assembling
General notes and information
- After dismantling the engine, clean all parts carefully.
- To reassemble the engine, carry out the dismantling operations in reverse order mentioned
above.
- Tight the nut/bolt on specified torque.
In addition, make sure to:
- Replace all seals and gaskets at each complete or partial engine rebuild.
- Lubricate all rotating parts and oil seals with engine oil prior to installation.
- Lubricate the oil filter mounting seal prior to filling the filter.
Mounting the balancing device with counter-rotating weight
Disassembling operation 58 to 66
Step 1
Assemble counterweight parts in the housing (2),
carrying out dismantling operations 64 to 66 in
reverse order. Align the positioning marks on the
gear (4) and counterweights (1) (indicated by the
arrows in fig.)
Step 2
The intermediate gear (3) must be installed with
the longer side of its hub towards the casing side.
Step 3
The holes for the lock pins (1) in the
counterweight shafts (2) must be aligned with the
corresponding holes in the casing.
Step 4
Install the counterweight assembly on the sump,
carrying out the operations 58 to 62 in reverse
order.
A1.60 MR306-10.2004-EN
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16. Engine disassembling & assembling
Engine assembling
Mounting the tappets and drive shaft with main bearing caps, bearing and thrust rings:
Checking axial play of drive shaft
Disassembling operation 52 to 53
Step 5
Install the tappets in their crankcase bores.
Step 6
Lubricate the main bearing seal with engine oil
and install the half shell bearings (3).
Step 7
Stick the semi circular thrust washers (1) to both
sides of the penultimate main bearing with
grease (2).
Step 8
Lubricate the upper surfaces of the main bearing
shell with engine oil and lower the crankshaft (1)
into position, taking care not to dislodge the semi-
circular thrust washers installed previously.
Step 9
Lubricate the crankshaft journals with engine oil
and fit the main bearing caps (3) with the half
shells (4), fitting the top semicircular thrust
washers (2) to the penultimate bearing cap.
Step 10
Rotate the crankshaft (1) a few times to allow the
parts to settle into position.
Step 11
Insert the main bearing cap bolts and screw in
until the head of the bolt is up against the cap.
MR306-10.2004-EN A1.61
17. Engine disassembling & assembling
Engine assembling
Mounting the tappets and drive shaft with main bearing caps, bearing and thrust rings:
Checking axial play of drive shaft
Step 12
Tighten all cap bolts (1) to a torque of 80Nm.
Step 13
Tighten each cap bolt (1) through a further 90°
using the tool 1035170088 (2).
Step 14
Check that the crankshaft end float does not
exceed the value specified.
A1.62 MR306-10.2004-EN
18. Engine disassembling & assembling
Engine assembling
Mounting the rear cover with seal and engine flywheel
Disassembling operation 51
Step 15
Fill the rear oil seal carrier (3) with outer seal.
Tighten the retaining bolt (2) to the specified
torque. Using a feeler gauge (1), check that the
crankshaft flange is coaxial with the carrier.
Step 16
Fit the inner rear oil seal using installer
1035170090 (1) and handgrip.
Step 17
Fit the flywheel and tighten the retaining bolts (1)
to a torque of 40Nm.
Step 18
Using tool 1035170088 (1), tighten each flywheel
bolt (2) through a further 60o
.
MR306-10.2004-EN A1.63
19. Engine disassembling & assembling
Engine assembling
Mounting the pistons complete with rings, pins, connecting rods, big end bearings:
Checking protrusion in relation to cylinder block face
Disassembling operation 48 to 49
Step 19
Lubricate pistons, rings and cylinder liners with
engine oil prior to fitting.
Step 20
Using the piston ring pliers (As shown in fig.) fit
the piston rings. Make sure that the piston ring
gaps are offset at 180°..
Step 21
Fit piston ring clamp to compress the rings,
making sure that the piston ring gaps remain in
the position specified in the previous point.
Step 22
Insert the piston / connecting rod into the cylinder
liner, checking that the connecting rod number
corresponds with the cylinder number and that
the number stamped on the connecting rod is
facing away from the camshaft.
Step 23
Fit the big-end caps (1), complete with shells, to
the crank pins and tighten the cap bolts (2) to a
torque of 40Nm.
Step 24
Using tool 292248 (1), tighten each big-end cap
bolt (2) through a further 60°.
Step 25
Rotate the engine on the stand through 180° and
clean the upper face of the cylinder block.
Bring the pistons (2), up to TDC and, using a dial
gauge with a magnetic base (1), check that the
piston protrusion from the cylinder block face is
within the tolerance limits.
A1.64 MR306-10.2004-EN
