3-Zyl. Dieselmotor

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Engine number
  1
• 1.2 Engine data
  1
• Removing and installing engine
  3
• 1 Removing and installing engine
  3
• 1.1 Removing engine
  3
• 1.2 Securing engine to assembly stand
  9
• 1.3 Notes on installing
  10
• 1.4 Assembly mountings
  11
• 1.5 Additional information and assembly work for vehicles with air conditioner
  12
• Crankshaft group
  13
• 1 Dismantling and assembling engine
  13
• 1.1 Assembly overview - toothed belt drive
  13
• 1.2 Assembly overview - crankcase
  15
• 1.3 Removing and installing poly V-belt
  16
• 2 Sealing flange and flywheel
  20
• 2.2 Assembly overview - sealing flange and flywheel, engine codes BMS, BWB
  22
• 2.3 Renewing crankshaft oil seal - pulley end
  23
• 2.4 Removing and installing sealing flange - pulley end
  24
• 2.5 Renewing crankshaft sealing flange - flywheel end, engine codes BMS, BWB
  27
• 3 Balancer shaft and retaining frame
  36
• 3.1 Assembly overview - balancer shaft and retaining frame
  36
• 3.2 Removing and installing balancer shaft
  38
• 4 Crankshaft
  43
• 4.1 Assembly overview - crankshaft
  43
• 4.2 Crankshaft dimensions
  44
• 5 Pistons and conrods
  46
• 5.1 Assembly overview - pistons and conrods
  46
• 5.2 Separating new conrods
  48
• 5.3 Checking pistons, piston rings and cylinder bores
  48
• 5.4 Checking piston projection at TDC
  50
• 5.5 Piston and cylinder dimensions
  51
• Cylinder head, valve gear
  52
• 1 Cylinder head
  52
• 1.1 Assembly overview - cylinder head
  52
• 1.2 Removing, installing and tensioning toothed belt
  56
• 1.3 Removing and installing cylinder head
  66
• 1.4 Checking compression
  70
• 2 Valve gear
  73
• 2.1 Assembly overview - valve gear
  73
• 2.2 Reworking valve seats
  76
• 2.3 Checking valve guides
  78
• 2.4 Renewing valve stem seals
  78
• 2.5 Removing and installing camshaft
  80
• 2.6 Removing and installing camshaft oil seal
  84
• Lubrication
  87
• 1 Engine oil
  87
• 1.1 Oil capacities
  87
• 1.2 Checking engine oil level
  87
• 2 Parts of lubrication system
  88
• 2.1 Assembly overview - parts of lubrication system
  88
• 2.2 Assembly overview - oil filter bracket
  91
• 2.3 Removing and installing oil sump
  92
• 2.4 Checking oil pressure and oil pressure switch
  93
• Cooling
  96
• 1 Removing and installing parts of cooling system
  96
• 1.1 Assembly overview - parts of cooling system, body side
  96
• 1.2 Assembly overview - parts of cooling system, engine side
  98
• 1.3 Coolant hose schematic diagram
  99
• 1.4 Draining and filling coolant
  101
• 1.5 Removing and installing radiator
  105
• 1.6 Removing and installing coolant pump
  106
• 1.7 Removing and installing thermostat
  108
• 1.8 Checking cooling system for leaks
  109
• 1.9 Checking engine oil cooler for leaks
  111
• Fuel supply system
  114
• 1 Removing and installing parts of fuel supply system
  114
• 1.1 Safety precautions when working on fuel supply system
  115
• 1.2 Rules for cleanliness
  115
• 1.3 Assembly overview - fuel tank with attachments
  116
• 1.4 Removing and installing fuel tank
  118
• 1.5 Assembly overview - fuel filter
  119
• 1.6 Removing and installing fuel cooler
  122
• 1.7 Removing and installing fuel delivery unit
  122
• 1.8 Removing and installing fuel gauge sender G
  124
• 1.9 Checking fuel pump
  124
• 1.10 Assembly overview - accelerator mechanism
  125
• 1.11 Checking tandem pump
  126
• 1.12 Removing and installing tandem pump
  130
• Turbocharging/supercharging
  133
• 1 Charge air system with turbocharger
  133
• 1.1 Safety precautions
  133
• 1.2 Rules for cleanliness
  134
• 1.3 Installing hose connections with connector couplings
  134
• 1.4 Hose connections with spring band ring
  135
• 1.5 Assembly overview - turbocharger
  135
• 1.6 Removing and installing turbocharger, engine codes BMS, BWB
  140
• 1.7 Assembly overview - parts of charge air cooling
  142
• 1.8 Checking charge air system for leaks
  144
• Mixture preparation - injection
  147
• 1 Repairing diesel direct injection system
  147
• 1.1 Safety precautions
  147
• 1.2 Rules for cleanliness
  148
• 1.3 Assembly overview - intake manifold with intake manifold flap
  148
• 1.4 Assembly overview - air filter
  152
• 1.5 Assembly overview - unit injector
  152
• 1.6 Removing and installing unit injector
  154
• 1.7 Adjusting non-contact gap of unit injectors
  156
• 1.8 Removing and installing O-rings for unit injector
  156
• 2 Engine control unit
  159
• 2.1 Removing and installing engine control unit
  159
• 2.4 Reading and clearing engine control unit event memory
  162
• 2.5 Adapting functions and components
  163
• Exhaust system
  165
• 1 Exhaust system
  165
• 1.1 Assembly overview - front exhaust pipe with catalytic converter and silencer
  165
• 1.2 Assembly overview - front exhaust pipe with particulate filter
  167
• 1.3 Assembly overview - silencer, vehicles with particulate filter
  168
• 1.4 Removing and installing front exhaust pipe with particulate filter
  169
• 1.5 Aligning exhaust system free of stress
  170
• 2 Exhaust gas recirculation system
  173
• 2.1 Assembly overview - parts of exhaust gas recirculation system, engine code AMF
  173
• 2.3 Assembly overview - parts of exhaust gas recirculation system, engine codes BMS, BWB
  175
• 2.6 Vacuum hose assembly
  178
• Glow plug system
  180
• 1 Checking glow plug system
  180
• 1.1 Removing, installing and checking glow plugs
  180
• 1.2 Characteristics of ceramic glow plugs
  181
• 1.3 Removing, installing and checking ceramic glow pin plugs
  181