Page 323 - CTS - Mechanic Diesel - TP

MECHANIC DIESEL - CITS

9 Disconnect the intercooler hoses, Fuel inlet and return hoses, Radiator inlet and outlet hoses and Water
engine outlet hose.
10 Disconnect the electrical wiring connections of MAP sensor, A/F Sensor, ECT sensor, CMP&CKP sensor,
Injectors, Glow plug, EGR valve, Oil pressure switch, Fuel pressure regulator, fuel pressure sensor, Alternator,
Starter and engine Ground.
11 Remove the exhaust pipe line.
12 Remove clutch and gear shifting lever connections.
13 Remove any other parts which obstructs to remove the engine.

14 Loosen the engine mounting bolt and support the engine by engine hoist.
15 Remove the engine from Vehicle.
16 Fix the engine on engine supporting stand.
17 Remove engine accessories like alternaror, power steering pump, AC compressor pump and starter motor.
18 Remove oil pan.
19 Remove water pump, Inlet and Exhaust manifold, remove high pressure pipe lines from pump to common rail
and common rail to injectors.
20 Remove common rail and CRDI injectors.
21 Remove crank shaft pulley, Timing chain cover, timing chain tensioner and Timing chain.

22 Remove cam shaft housing assembly ,Vacuum pump and High pressure pump.
23 Remove camshaft timing sprocket, Timing gears and cam shaft.
24 Remove glow plugs, oil separator, oil pressure switch, CMP sensor, Hydraulic valve lash adjuster with valve
rocker arm.
25 Remove cylinder head bolts as per sequence and takeout the cylinder head and Head gasket.
26 Dismantle the cylinder head assembly and remove the valves, valve springs, Valve stem seal and valve spring
seat.
27 Remove connecting rod caps and remove the piston assembly from engine and keep as per sequence no
engine cylinders.
28 Dismantle the piston and connecting rod assembly.
29 Remove the Flywheel.
30 Remove the Main bearing caps, CKP sensor, crankshaft front and rear end supports.

31 Remove crankshaft.
Cleaning and Inspection
Remove the carbon particles deposited on the piston, valves, cylinder head combustion chamber and Intake and
exhaust ports.
Clean all the parts dismantled from the engine.
Clean the cylinder block and Cylinder head with water jet .Clean the oil and water passages with water jet and
compressed air.
Inspection of Parts

1 Checking of crankshaft
Check the crankshaft main journals and crank pin diameters for taper and ovality wear and cracks if any cracks
found or wear limit is out of specification of manufacturer, replace the crankshaft or recondition the crank shaft.
Check the crankshaft thrust play, if it is out of specification, Replace with oversize bearing.

2 Checking of Main bearings
Visually inspect the bearings for pitting, scoring, wear or any scratch. If necessary replace with standard size
bearing.

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CITS : Automotive - Mechanic Diesel - Exercise 17.4