Engine and engine auxiliaries repair

We started disassembly and defects detection of the engine.

Engine head was brought into the pieces for defects detection.

Pistons were extracted from the engine block. Piston ring was broken scratching cylinder surface. More detailed measuring to follow.

Fuel pump was completely disassembled for defects detection and repair.

All components of the fuel pump were prepared for assembling of the unit.

All suitable for further use components o the engine were prepared for assembling.

Using restored components we assembled cold start valve.

Using restored components inlet manifold unit was assembled.

Restored air filter canister was assembled.

Rubber inlay of crankshaft vibration damper was separated so this component we had to replace.

We disassembled for repair oil pressure check valve.

We received new valves required for engine head repair, which were delivered to specialist workshop to mate those with our engine head.

We received for assembling from specialized workshop machined main motor components - block and crankshaft.

We preassembled Powersteering fluid canister.

Restored air cleaner was preassembled using restored parts and new filter element.

Restored hatch was assembled using restored parts.

We acquired new components needed for exhaust system tailoring.

Current batch of parts was returned from galvanizing.

We started assembling of the engine installing machined block on the assembling rig.

New main bearing shells adequate to machined crankshaft were used for installation.

New pistons were paired to corresponding connection rods.

We started installation of the preassembled restored engine ancillaries. New components like gaskets, seals, chain and sprockets were used for assembling.

Assembling of the engine was continued installing new pistons, restored oil pump and oil pan.

Machined engine head comprising new valves and valve guides was received for assembling.

As engine head took dedicated place installation of all restored engine components was continued.

Restored engine front-end ancillaries were installed.

Engine was installed onto test rig for adjustments and tests.

Heating unit was installed onto the test rig for tests of all involved restored components.

All engine ancillaries were installed and connected to the power plant for tests.

Engine was started and initial adjustments were carried out. Run-in tests revealed that injection pump settings are out of range and it needs overhauling.

Arrived overhauled at German Bosch specialist workshop injection pump and paired set of injectors

We received for installation tested radiator with the new core.

We prepared for installation new fuel pump with restored ancillaries.

We cut away smashed segment of the exhaust pipe for repair.

As corrected segment of the pipe was welded into place weld seams were grinded and protective coating was applied.