3-cyl. Diesel engine (aluminium cylinder block), Mechanics

Chapter overview

• 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
  4
• 1.3 Securing engine to assembly stand
  6
• 1.4 Notes on installing
  7
• 1.5 Tightening torques
  8
• 1.6 Assembly mountings
  8
• Crankshaft group
  10
• 1 Dismantling and assembling engine
  10
• 1.1 Dismantling and assembling engine
  10
• 1.2 Removing and installing ribbed belt
  24
• 2 Removing and installing counterbalance shaft and retaining frame
  25
• 2.1 Removing and installing counterbalance shaft and retaining frame
  25
• 2.2 Removing and installing counterbalance shaft
  29
• 3 Removing and installing cylinder block, sealing flange and fly wheel
  33
• 3.1 Removing and installing cylinder block, sealing flange and fly wheel
  33
• 3.2 Renewing crankshaft oil seal -pulley end
  37
• 3.3 Removing and installing sealing flange, pulley end
  39
• 4 Dismantling and assembling pistons and conrods
  42
• 4.1 Dismantling and assembling pistons and conrods
  42
• 4.2 Checking piston projection at TDC
  50
• 4.3 Piston and cylinder dimensions
  51
• Cylinder head, Valve gear
  52
• 1 Removing and installing cylinder head
  52
• 1.1 Removing and installing cylinder head
  52
• 1.2 Removing, installing and tensioning toothed belt
  60
• 1.3 Dismantling and assembling intake manifold
  67
• 1.4 Removing and installing cylinder head
  68
• 1.5 Checking compression pressures
  72
• 2 Servicing valve gear
  74
• 2.1 Servicing valve gear
  74
• 2.2 Reworking valve seats
  81
• 2.3 Checking valve guides
  83
• 2.4 Renewing valve guides
  84
• 2.5 Renewing valve stem seals
  85
• 2.6 Removing and installing camshaft
  87
• 2.7 Removing and installing camshaft oil seal
  91
• Lubrication
  93
• 1 Removing and installing parts of the lubrication system
  93
• 1.1 Removing and installing parts of the lubrication system
  93
• 1.2 Removing and installing sump
  107
• 1.3 Checking oil pressure and oil pressure switch
  110
• Cooling system
  112
• 1 Removing and installing parts of cooling system
  112
• 1.1 Removing and installing parts of cooling system
  112
• 1.2 Parts of cooling system body side
  113
• 1.3 Parts of cooling system engine side
  116
• 1.4 Coolant hose connection diagram
  120
• 1.5 Draining and filling cooling system
  121
• 1.6 Removing and installing radiator
  124
• 1.7 Removing and installing coolant pump
  125
• 1.8 Removing and installing thermostat
  127
• Fuel supply system
  129
• 1 Removing and installing parts of fuel supply system
  129
• 1.1 Removing and installing parts of fuel supply system
  129
• 1.2 Removing and installing fuel tank with its attachments
  129
• 1.3 Servicing fuel filter
  134
• 1.4 Safety precautions when working on the fuel supply system
  137
• 1.5 Rules for cleanliness
  138
• 1.6 Removing and installing fuel cooler
  138
• 1.7 Removing and installing fuel tank
  139
• 1.8 Servicing accelerator mechanism
  141
• 1.9 Checking accelerator pedal position sender
  144
• 1.10 Adjusting pedal position sender
  149
• 1.11 Checking tandem pump
  149
• 1.12 Removing and installing tandem pump
  152
• Charging
  155
• 1 Charge air system with turbocharger
  155
• 1.1 Charge air system with turbocharger
  155
• 1.2 Safety precautions
  155
• 1.3 Rules for cleanliness
  155
• 1.4 Removing and installing turbocharger with attachments
  155
• 1.5 Removing and installing parts of charge air cooling
  160
• 1.6 Hose connection diagram for charge pressure control
  162
• 2 Checking charge pressure control
  164
• 2.1 Checking charge pressure control
  164
• Exhaust system
  169
• 1 Removing and installing parts of exhaust system
  169
• 1.1 Removing and installing parts of exhaust system
  169
• 2 Exhaust gas recirculation system
  172
• 2.1 Exhaust gas recirculation system
  172
• 2.2 Removing and installing parts of exhaust gas recirculation system
  173
• 2.3 Vacuum hose connection diagram
  177
• 2.4 Checking exhaust gas recirculation valve (mechanical)
  179
• 2.5 Checking exhaust gas recirculation
  180