Dismantling the diesel engine of the KAMAZ-740.10 car
Before disassembly, the diesel engine must be cleaned of dirt and oil, washed with kerosene or a degreasing solution
For washing, it is recommended to use washing solutions MS-6 or MS-8 TU 6-15-978-76 with a concentration of 20-30 g/l at a temperature of 90...100 °C.
Then blow out the diesel with compressed air.
Removal of devices and units from the diesel engine is recommended to be carried out on a stationary rotary stand.
The gearbox must be removed from the diesel before installing the diesel on the stand.
Turning of the diesel engine around the horizontal axis of the stand is carried out using a worm gear located on the stand.
During disassembly or assembly, the diesel engine must be fixed in any position when braking the worm gear.
In the process of disassembling the diesel engine, all parts suitable for further operation should be protected from damage
Parts and normals removed from the diesel engine should be placed in a specially prepared container in which they are transported to the operations of washing, checking and troubleshooting.
Most diesel parts are interchangeable, but some require a custom fit with a mating part.
When assembling parts that have not been repaired or replaced, they must be installed in their places where they have run in. To do this, they must be marked during disassembly in any way that does not damage the parts.
With an impersonal repair method, it is forbidden to disassemble the connecting rod caps with connecting rods, main bearing caps with a cylinder block, since these parts are processed as an assembly.
The crankshaft, flywheel and clutch can be dismantled as these parts are balanced separately.
Diesel disassembly is carried out in the following sequence:
Unscrew the clamp from the branch pipe of the expansion tank (Fig. 1).
Unscrew the fastening clamp and remove the expansion tank if it was not dismantled when shooting the diesel.
Loosen the tension of the alternator drive belt and remove the belt (fig. 2).
Then, having unscrewed the nuts securing the exhaust manifold, remove it (Fig. 3).
Remove the shift lever support
Remove the two bolts of the alternator bracket and remove the alternator (fig. 4).
Remove the coolant pump.
Remove thermostat housing
Unscrew the bolts and remove the fluid coupling with the front cover of the block.
Remove the front cover gasket.
Unscrew the fuel supply pipes from the injection pump (Fig. 5). Remove injection pump.
Using a universal puller (fig. 6) …
…remove the injectors from the diesel engine (Fig. 7).
Unscrew the inlet pipes and water collection pipes.
Remove the cylinder head bolts, remove the cylinder heads and gaskets (Fig. 8).
Remove the compressor (fig. 9).
Remove the power steering pump (Fig. 10).
Dismantle the clutch (fig. 11).
Remove the eight flywheel mounting bolts and remove the flywheel (fig. 12).
Remove the flywheel housing mounting bolts and remove the flywheel housing (Fig. 13).
Unscrew the bolts and remove the oil pan and oil pump (Fig. 14).
Remove the connecting rod caps with liners; (Fig. 15)
- remove the connecting rods complete with pistons from the cylinders and put the connecting rod caps in their places. We look at the article "Repair of connecting rod and piston group".
When disassembling the diesel engine, the pistons complete with connecting rods must be removed only upwards. Before removing the pistons, it is necessary to remove carbon deposits from the top of the cylinder liner.
Unscrew the coupling bolts of the yokes 1 (Fig. 16). Loosen the bolts securing the main bearing caps 2 and remove them together with the bearing shells.
Remove the crankshaft (fig. 17).
When replacing parts of the sleeve-piston group and the crank mechanism, special attention should be paid to the size groups of parts.
Remove the compression and oil scraper rings from the pistons using tool И804.03.000.
Remove the circlips from the piston bosses using round nose pliers; press out the piston pins. We look at the article "Connecting rod-piston repair
Through the holes in the gear, unscrew the three bolts, and then, turning the camshaft, remove it from the cylinder block.
Press the cylinder liners out of the block using a tool.
If there is no fixture, you can knock out the shells using an aluminum or bronze drift.
After disassembly, all parts of the diesel engine must be washed and blown with compressed air.
Before tightening the main caps, you need to start the tie bolts, and then tighten the main cap bolts.
Tightening of the main caps should be done after replacing all the liners, the tightening order matters.
You need to tighten from the middle, from the middle root cover and move to the edges.
Installation location - Tightening torques
Block tie bolt 100 - 110 Nm (10 - 11 kgcm)
Cylinder head bolt 190 - 210 Nm (19 - 21 kgcm)
Main bearing cap bolt 210 - 235 (21 - 23.5 kgcm)
Flywheel bolt 150 - 170 (15 - 17 kgcm)
Flywheel housing bolt 90 - 110 (9 - 10 kgcm)
Connecting rod bolt - Up to 0.25 - 0.27 mm extension
After clamping each cover, check the rotation of the shaft.
The rotation should be free.