Contents: How to use the contents of this…↡ Engine Description ↡ Basic repair operations that can be…↡
How to use the contents of this chapter
This part of Chapter 2 describes the types of repairs that can be performed on the engine without removing it from the vehicle. If the engine has been removed from the vehicle and disassembled as described in part G this chapter, preliminary dismantling work can be skipped.
Note that although some types of work, such as repairing the piston-to-connecting-rod connection, are physically feasible without removing the engine from the vehicle, such operations are usually not performed separately. A number of additional operations are usually required (not to mention cleaning the parts and oil lines). For this reason, all such types of work are classified as major repairs, the description of which is given in part G of this chapter.
Part G describes the procedure for removing the power unit (engine + gearbox) from the vehicle and all types of repair work that can be performed after this.
Engine Description
The car can be equipped with a 4-cylinder or 5-cylinder diesel engine; both of these engines are basically similar, the main difference being the number of cylinders.
The engine has a single overhead camshaft, is located in line with the gearbox and is located at the front of the car.
In a 4-cylinder engine, the crankshaft rests on five main bearings on a cast-iron cylinder block. Axial movement of the crankshaft is prevented by thrust half rings on both sides of main bearing No.3. Accordingly, in a 5-cylinder engine, the crankshaft rests on six main bearings, and thrust half rings are located on both sides of bearing No.4. The connecting rods are connected to the crankshaft by bearings consisting of two horizontally cut halves. The connecting rods are connected to the pistons by means of floating piston pins secured in the pistons by split spring rings. The light alloy pistons have three piston rings: two compression rings and one oil scraper ring. The camshaft is driven by a double drive chain from the crankshaft sprocket. The same chain drives the high-pressure fuel pump.
The camshaft is supported by bearings in the cylinder head and acts on the valves directly through hydraulic valve lifters.
The oil pump is chain driven from the front end of the crankshaft.
Basic repair operations that can be performed without removing the engine from the vehicle
The following operations can be performed without removing the engine from the vehicle:
- a) Removing and installing the cylinder head.
- b) Removing and installing the chain and sprockets of the camshaft drive.
- c) Removing and installing the camshaft
- d) Removing and installing the oil pan
- d) Removal and installation of connecting rod bearings, connecting rods and pistons *
- e) Removing and installing the oil pump
- g) Replacement of power unit supports
- c) Removing and installing the flywheel of the leading faceplate.
* Although it is possible to remove these parts without removing the engine from the vehicle, for reasons of convenience and cleanliness, it is recommended to perform these operations on the engine removed from the vehicle.