3-cylinder diesel engine

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Engine number
  1
• 1.2 Engine data
  1
• Self-diagnosis
  2
• 1 Self-diagnosis
  2
• 1.1 Features of self-diagnosis
  2
• 1.2 Technical data of self-diagnosis
  2
• 2 Fault memory
  7
• 2.1 Read fault memory
  7
• 2.2 Erase fault memory
  8
• 3 Fault table: Fault codes 00515...01282
  10
• 4 Fault table: Fault codes 16485...18076
  13
• 5 Final control diagnosis
  27
• 5.1 Performing final control diagnosis
  27
• 6 Measured value blocks
  30
• 6.1 Safety precautions
  30
• 6.2 Reading measured value block
  30
• 6.3 Measured values at idling speed
  31
• 6.4 Measured values at full throttle
  39
• Removing and installing engine
  44
• 1 Removing and installing engine
  44
• 1.1 Notes on removing
  45
• 1.2 Securing engine to assembly stand
  46
• 1.3 Notes on installing
  47
• 1.4 Assembly mountings
  48
• 1.5 Additional notes and assembly work for vehicles with air conditioner
  49
• Crankshaft group
  50
• 1 Dismantling and assembling engine
  50
• 1.1 Assembly overview
  50
• 1.2 Removing and installing poly V-belt
  55
• 2 Removing and installing sealing flange and flywheel
  58
• 2.1 Assembly overview
  58
• 2.2 Renewing crankshaft oil seal - pulley end
  59
• 2.3 Removing and installing sealing flange - pulley end
  60
• 3 Balancer shaft and retaining frame
  63
• 3.1 Assembly overview
  63
• 3.2 Removing and installing balancer shaft
  64
• 4 Removing and installing crankshaft
  69
• 4.1 Crankshaft dimensions
  70
• 5 Pistons and conrods
  71
• 5.1 Assembly overview - pistons and conrods
  71
• 5.2 Checking piston projection at TDC
  73
• 5.3 Piston and cylinder dimensions
  75
• Cylinder head, valve gear
  76
• 1 Cylinder head
  76
• 1.1 Assembly overview - cylinder head
  76
• 1.2 Removing, installing and tensioning toothed belts
  79
• 1.3 Removing and installing cylinder head
  84
• 1.4 Checking compression
  87
• 2 Valve gear
  90
• 2.1 Assembly overview - valve gear
  90
• 2.2 Reworking valve seats
  92
• 2.3 Checking valve guides
  94
• 2.4 Renewing valve guides
  94
• 2.5 Renewing valve stem seals
  95
• 2.6 Removing and installing camshaft
  97
• 2.7 Removing and installing camshaft oil seal
  101
• Lubrication
  104
• 1 Parts of lubrication system
  104
• 1.1 Engine oil
  104
• 1.2 Assembly overview - parts of lubrication system
  104
• 1.3 Removing and installing sump
  109
• 1.4 Checking oil pressure and oil pressure switch
  110
• Cooling
  113
• 1 Parts of cooling system
  113
• 1.1 Assembly overview - parts of cooling system, body side
  113
• 1.2 Assembly overview - parts of cooling system, engine side
  115
• 1.3 Coolant hose schematic diagram
  116
• 1.4 Draining and filling coolant
  117
• 1.5 Removing and installing radiator
  120
• 1.6 Removing and installing coolant pump
  121
• 1.7 Removing and installing thermostat
  122
• Fuel supply system
  124
• 1 Parts of fuel supply system
  124
• 1.1 Assembly overview - fuel tank with attachments
  124
• 1.2 Assembly overview - fuel filter
  126
• 1.3 Safety precautions when working on fuel supply system
  128
• 1.4 Rules for cleanliness
  128
• 1.5 Removing and installing fuel cooler
  128
• 1.6 Removing and installing fuel tank
  129
• 1.7 Accelerator mechanism
  130
• 1.8 Checking accelerator position sender G79
  133
• 1.9 Adjusting accelerator position sender G79
  136
• 1.10 Checking tandem pump
  137
• 1.11 Removing and installing tandem pump
  139
• Turbocharging/supercharging
  142
• 1 Charge air system with turbocharger
  142
• 1.1 Safety precautions
  142
• 1.2 Rules for cleanliness
  142
• 1.3 Removing and installing turbocharger with attachments
  142
• 1.4 Removing and installing parts of charge air cooling
  145
• 1.5 Charge pressure control hose routing diagram
  147
• 2 Checking charge pressure system
  148
• 2.1 Checking charge pressure control
  148
• 2.2 Checking charge pressure control valve vacuum unit
  152
• 2.3 Removing and installing vacuum unit for charge pressure control valve
  153
• Mixture preparation - injection
  154
• 1 Repairing diesel direct injection system
  154
• 1.1 Safety precautions
  154
• 1.2 Rules for cleanliness
  154
• 1.3 Fitting locations overview
  155
• 1.4 Repairing intake manifold flap
  156
• 1.5 Servicing unit injector
  156
• 1.6 Removing and installing O-rings for unit injector
  157
• 1.7 Removing and installing unit injector
  159
• 2 Checking components and functions
  164
• 2.1 Checking voltage supply for diesel direct injection system
  164
• 2.2 Checking engine speed sender G28
  164
• 2.3 Checking intake manifold pressure sender G71 and altitude sender F96
  165
• 2.4 Checking coolant temperature sender G62
  168
• 2.5 Checking brake light switch F and brake pedal switch F47
  169
• 2.6 Checking clutch pedal switch F36
  170
• 2.7 Checking intake manifold temperature sender G72
  172
• 2.8 Checking fuel temperature sender G81
  173
• 2.9 Checking air mass meter G70
  175
• 2.10 Checking intake manifold flap change-over
  177
• 2.11 Checking unit injector valves
  178
• 2.12 Checking camshaft position Hall sender G40
  181
• 3 Checking additional signals
  183
• 3.1 Checking speed signal
  183
• 3.2 Checking signal from/to air conditioning system
  184
• 3.3 Checking speed signal
  187
• 3.4 Checking cruise control system (CCS)
  187
• 3.5 Checking data bus
  189
• 4 Renewing, coding and adapting engine control unit
  191
• 4.1 Renewing diesel direct injection system control unit J248
  191
• 4.2 Coding diesel direct injection system control unit J248
  191
• Exhaust system
  194
• 1 Parts of exhaust system
  194
• 1.2 Assembly overview - Silencer with mountings
  195
• 2 Exhaust gas recirculation system
  196
• 2.1 Assembly overview - parts of exhaust gas recirculation
  196
• 2.2 Schematic diagram for vacuum hoses
  197
• 2.3 Checking exhaust gas recirculation valve
  197
• 2.4 Checking exhaust gas recirculation
  198
• Glow plug system
  202
• 1 Glow plug system
  202
• 1.1 Checking glow plug system
  202
• 1.2 Checking glow plugs
  203