3-cylinder diesel engine (cast-iron cylinder block)

Kapitelübersicht

• Technical data
  1
• 1 Technical data
  1
• 1.1 Engine number
  1
• 1.2 Engine data
  1
• Removing and installing engine
  2
• 1 Removing and installing engine
  2
• 1.1 Notes on removing
  3
• 1.2 Securing engine to assembly stand
  4
• 1.3 Notes on installing
  5
• 1.4 Torque settings
  6
• 1.5 Assembly mountings
  6
• 1.6 Additional notes and assembly work for vehicles with air conditioner
  7
• Crankshaft group
  8
• 1 Dismantling and assembling engine
  8
• 1.1 Assembly overview
  8
• 1.2 Removing and installing poly V-belt
  14
• 2 Removing and installing sealing flange and flywheel
  16
• 2.1 Renewing crankshaft oil seal - pulley end
  17
• 2.2 Removing and installing sealing flange - pulley end
  18
• 3 Removing and installing balancer shaft and retaining frame
  21
• 3.1 Removing and installing balancer shaft
  22
• 4 Removing and installing crankshaft
  27
• 4.1 Crankshaft dimensions
  28
• 5 Dismantling and assembling pistons and conrods
  29
• 5.1 Checking piston projection at TDC
  32
• 5.2 Piston and cylinder dimensions
  33
• Cylinder head, valve gear
  34
• 1 Removing and installing cylinder head
  34
• 1.1 Removing, installing and tensioning toothed belts
  37
• 1.2 Removing and installing cylinder head
  44
• 1.3 Checking compression
  47
• 2 Repairing valve gear
  50
• 2.1 Reworking valve seats
  53
• 2.2 Checking valve guides
  54
• 2.3 Renewing valve stem seals
  55
• 2.4 Removing and installing camshaft
  56
• 2.5 Removing and installing camshaft oil seal
  60
• Lubrication
  63
• 1 Removing and installing parts of lubrication system
  63
• 1.1 Engine oil
  63
• 1.2 I Assembly overview - parts of lubrication system
  63
• 1.3 Part II Assembly overview - oil filter and oil cooler
  66
• 1.4 Part III Assembly overview - oil supply line
  67
• 1.5 Removing and installing sump
  69
• 1.6 Checking oil pressure and oil pressure switch
  70
• Cooling
  73
• 1 Removing and installing parts of cooling system
  73
• 1.1 Parts of cooling system, body side
  73
• 1.2 Parts of cooling system - engine side
  75
• 1.3 Coolant hose schematic diagram
  76
• 1.4 Draining and filling coolant
  77
• 1.5 Removing and installing radiator
  80
• 1.6 Removing and installing coolant pump
  81
• 1.7 Removing and installing thermostat
  82
• Fuel supply system
  85
• 1 Removing and installing parts of fuel supply system
  85
• 1.1 Removing and installing fuel tank with attachments
  85
• 1.2 Repairing fuel filter
  87
• 1.3 Safety precautions when working on fuel supply system
  88
• 1.4 Removing and installing fuel cooler
  88
• 1.5 Removing and installing fuel tank
  89
• 1.6 Repairing accelerator mechanism
  90
• 1.7 Checking accelerator position sender G79
  93
• 1.8 Adjusting accelerator position sender G79
  97
• 1.9 Checking tandem pump
  98
• 1.10 Removing and installing tandem pump
  100
• Turbocharging/supercharging
  103
• 1 Charge air system with turbocharger
  103
• 1.1 Safety precautions
  103
• 1.2 Rules for cleanliness
  103
• 1.3 Removing and installing turbocharger with attachments
  103
• 1.4 Removing and installing parts of charge air cooling
  107
• 1.5 Charge pressure control hose routing diagram
  108
• 2 Checking charge pressure system
  109
• 2.1 Checking charge pressure control valve vacuum unit
  109
• 2.2 Removing and installing vacuum unit for charge pressure control valve
  109
• 3 Checking charge pressure control
  111
• 3.1 Checking charge pressure control solenoid valve N75
  114
• Mixture preparation - injection
  116
• 1 Repairing diesel direct injection system
  116
• 1.1 Safety precautions
  116
• 1.2 Rules for cleanliness
  117
• 1.3 Fitting locations overview
  117
• 1.4 Repairing intake manifold flap
  118
• 1.5 Servicing unit injector
  120
• 1.6 Removing and installing O-rings for unit injector
  120
• 1.7 Removing and installing unit injector
  122
• 2 Checking components and functions
  128
• 2.1 Checking voltage supply for diesel direct injection system
  128
• 2.2 Checking engine speed sender G28
  128
• 2.3 Checking intake manifold pressure sender G71 and altitude sender F96
  129
• 2.4 Checking coolant temperature sender G62
  131
• 2.5 Checking brake light switch F and brake pedal switch F47
  133
• 2.6 Checking clutch pedal switch F36
  134
• 2.7 Checking intake manifold temperature sender G72
  135
• 2.8 Checking fuel temperature sender G81
  137
• 2.9 Checking air mass meter G70
  139
• 2.10 Checking intake manifold flap change-over
  141
• 2.11 Checking intake manifold flap motor V157
  142
• 2.12 Checking unit injector valves
  144
• 2.13 Checking camshaft position Hall sender G40
  146
• 3 Checking additional signals
  148
• 3.1 Checking speed signal
  148
• 3.2 Checking signal from/to air conditioning system
  149
• 3.3 Checking speed signal
  152
• 3.4 Checking cruise control system (CCS)
  152
• 3.5 Checking data bus
  154
• 4 Renewing, coding and matching engine control unit
  160
• 4.1 Renewing engine control unit
  160
• 4.2 Coding engine control unit
  160
• 4.3 Adapting engine control unit to electronic immobilizer
  161
• Exhaust system
  163
• 1 Removing and installing parts of exhaust system
  163
• 1.1 Front exhaust pipe with catalytic converter and attachments
  163
• 1.2 Silencer with mountings
  164
• 2 Exhaust gas recirculation system
  165
• 2.1 Removing and installing parts of exhaust gas recirculation system
  165
• 2.2 Schematic diagram for vacuum hoses
  166
• 2.3 Checking exhaust gas recirculation valve
  166
• 2.4 Checking exhaust gas recirculation
  167
• Glow plug system
  171
• 1 Checking glow plug system
  171
• 1.1 Checking glow plugs
  172