6-cyl. Diesel engine, Mechanics

Kapitelübersicht

• Technical data
  1
• 1 Technical data
  1
• 1.1 Technical data
  1
• 1.2 Engine number
  1
• 1.3 Engine data
  1
• Removing and installing engine
  3
• 1 Removing and installing engine
  3
• 1.1 Removing and installing engine
  3
• 1.2 Notes on removing
  5
• 1.3 Notes on installing
  9
• 1.4 Tightening torques
  11
• 1.5 Front engine mounting
  13
• 1.6 Electro/hydraulic engine mounting, left and right
  14
• 1.7 Additional information and removal instructions for vehicles with air conditioner
  16
• Crankshaft group
  17
• 1 Dismantling and assembling engine
  17
• 1.1 Dismantling and assembling engine
  17
• 1.2 Removing and installing ribbed belt
  32
• 1.3 Removing and installing bracket for vane pump and oil cooler
  35
• 1.4 Removing, installing and tensioning toothed belts
  37
• 1.5 Removing toothed belt from camshaft sprockets
  45
• 2 Removing and installing sealing flanges and flywheel/drive plate
  53
• 2.1 Removing and installing sealing flanges and flywheel/drive plate
  53
• 2.2 Renewing crankshaft oil seal -belt pulley end
  57
• 2.3 Removing and installing front sealing flange
  59
• 2.4 Removing and installing dual mass flywheel
  62
• 2.5 Removing and installing drive plate
  63
• 3 Removing and installing crankshaft
  65
• 3.1 Removing and installing crankshaft
  65
• 3.2 Crankshaft dimensions
  70
• 3.3 Removing and installing sprocket
  70
• 4 Dismantling and assembling pistons and conrods
  72
• 4.1 Dismantling and assembling pistons and conrods
  72
• 4.2 Checking piston projection at TDC
  79
• 4.3 Piston and cylinder dimensions
  80
• Cylinder head, Valve gear
  82
• 1 Removing and installing cylinder head
  82
• 1.1 Removing and installing cylinder head
  82
• 1.2 Removing and installing front intake manifold
  87
• 1.3 Removing and installing left intake manifold
  88
• 1.4 Removing and installing right intake manifold
  90
• 1.5 Removing and installing left cylinder head cover
  92
• 1.6 Removing and installing cylinder head cover
  94
• 1.7 Removing left cylinder head
  97
• 1.8 Removing right cylinder head
  100
• 1.9 Installing cylinder head
  104
• 1.10 Checking compression pressures
  107
• 2 Servicing valve mechanism
  108
• 2.1 Servicing valve mechanism
  108
• 2.2 Check axial clearance of camshafts
  115
• 2.3 Replacing camshaft oil seal
  116
• 2.4 Removing and installing camshafts
  118
• 2.5 Checking hydraulic compensation elements
  122
• 2.6 Renewing valve stem seals
  123
• 2.7 Checking valve guides
  125
• Lubrication
  126
• 1 Removing and installing parts of the lubrication system
  126
• 1.1 Removing and installing parts of the lubrication system
  126
• 1.2 Removing and installing oil filter bracket
  135
• 1.3 Removing and installing oil sump - lower part
  137
• 1.4 Removing and installing oil pump
  139
• 1.5 Removing and installing oil sump - upper part
  143
• 1.6 Renewing oil check valve
  147
• 1.7 Removing and installing oil cooler
  148
• 1.8 Checking oil pressure and oil pressure switch
  150
• Cooling system
  153
• 1 Removing and installing parts of cooling system
  153
• 1.1 Removing and installing parts of cooling system
  153
• 1.2 Parts of cooling system body side
  154
• 1.3 Coolant pump and thermostat
  157
• 1.4 Coolant pipes - overview
  159
• 1.5 Draining and filling coolant
  161
• 1.6 Removing and installing coolant pump
  165
• 1.7 Removing and installing thermostat
  167
• 1.8 Removing and replacing front coolant pipe
  173
• 1.9 Removing and replacing left upper and lower coolant pipe
  174
• 1.10 Removing and replacing right coolant pipe
  176
• 1.11 Removing and installing radiator
  176
• Fuel supply system
  178
• 1 Removing and installing parts of fuel supply system
  178
• 1.1 Removing and installing parts of fuel supply system
  178
• 1.2 Removing and installing fuel tank with its attachments
  179
• 1.3 Servicing fuel filter
  193
• 1.4 Safety precautions when working on the fuel supply system
  195
• 1.5 Rules for cleanliness
  195
• 1.6 Emptying fuel tank
  195
• 1.7 Removing and installing fuel tank
  196
• 1.8 Checking low fuel level sender
  198
• 1.9 Removing and installing fuel gauge sender
  200
• 1.10 Removing and installing fuel delivery unit
  201
• 1.11 Removing and installing suction jet pump
  205
• 1.12 Checking fuel pump
  208
• 1.13 Bleeding fuel system
  211
• 2 Accelerator mechanism
  213
• 2.1 Accelerator mechanism
  213
• 2.2 Servicing accelerator mechanism
  213
• 2.3 Checking accelerator pedal position sender
  216
• 2.4 Adjusting pedal position sender (vehicles >05.99)
  222
• Charging
  223
• 1 Charge air system with turbocharger
  223
• 1.1 Charge air system with turbocharger
  223
• 1.2 Removing and installing turbocharger with attachments
  223
• 1.3 Removing and installing turbocharger
  226
• 1.4 Removing and installing compensator
  228
• 1.5 Removing and installing parts of charge air cooling system
  230
• 1.6 Removing and installing charge air cooler
  232
• 1.7 Charge pressure control hose routing diagram
  233
• 1.8 Rules for cleanliness
  234
• 2 Checking charge pressure system
  235
• 2.1 Checking charge pressure system
  235
• 2.2 Checking turbocharger and charge pressure control
  235
• 2.3 Checking pressure unit for charge pressure regulating valve
  240
• 2.4 Checking charge pressure control solenoid valve
  242
• Exhaust system
  246
• 1 Removing and installing parts of exhaust system
  246
• 1.1 Removing and installing parts of exhaust system
  246
• 1.3 Front exhaust pipe and catalyst with attachments
  250
• 1.4 Silencer with mountings
  252
• 1.5 Removing and installing left exhaust manifold with front exhaust pipe
  254
• 1.6 Removing and installing right exhaust manifold with front exhaust pipe
  256
• 2 Exhaust gas recirculation system
  258
• 2.1 Exhaust gas recirculation system
  258
• 2.2 Vacuum hose connection diagram
  258
• 2.3 Checking exhaust gas recirculation valve (mechanical)
  259
• 2.4 Removing and installing exhaust gas recirculation valve
  260
• 2.5 Checking exhaust gas recirculation
  261