3-cylinder diesel engine (aluminium cylinder block)

Chapter overview

• 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
  7
• Crankshaft group
  8
• 1 Dismantling and assembling engine
  8
• 1.1 Assembly overview
  8
• 1.2 Removing and installing poly V-belt
  13
• 2 Removing and installing balancer shaft and retaining frame
  14
• 2.1 Removing and installing balancer shaft
  15
• 3 Removing and installing cylinder block, sealing flange and flywheel
  20
• 3.1 Renewing crankshaft oil seal on belt pulley end
  21
• 3.2 Removing and installing sealing flange on pulley end
  22
• 4 Dismantling and assembling pistons and conrods
  25
• 4.1 Disconnecting conrod
  27
• 4.2 Checking piston projection at TDC
  28
• 4.3 Piston and cylinder dimensions
  29
• Cylinder head, valve gear
  30
• 1 Removing and installing cylinder head
  30
• 1.1 Removing, installing and tensioning toothed belts
  33
• 1.2 Dismantling and assembling intake manifold
  38
• 1.3 Removing and installing cylinder head
  40
• 1.4 Compression test
  44
• 2 Repairing valve gear
  47
• 2.1 Reworking valve seats
  49
• 2.2 Checking valve guides
  51
• 2.3 Renewing valve guides
  52
• 2.4 Renewing valve stem seals
  52
• 2.5 Removing and installing camshaft
  54
• 2.6 Removing and installing camshaft oil seal
  58
• Lubrication
  61
• 1 Removing and installing parts of lubrication system
  61
• 1.1 Engine oil
  61
• 1.2 Removing and installing sump
  68
• 1.3 Checking oil pressure and oil pressure switch
  69
• Cooling
  71
• 1 Removing and installing parts of cooling system
  71
• 1.1 Parts of cooling system, body side
  71
• 1.2 Parts of cooling system - engine side
  73
• 1.3 Coolant hose schematic diagram
  74
• 1.4 Draining and filling coolant
  75
• 1.5 Removing and installing radiator
  78
• 1.6 Removing and installing coolant pump
  79
• 1.7 Removing and installing thermostat
  80
• Fuel supply system
  82
• 1 Removing and installing parts of fuel supply system
  82
• 1.1 Removing and installing fuel tank with attached components
  82
• 1.2 Repairing fuel filter
  84
• 1.3 Safety precautions when working on fuel supply system
  85
• 1.4 Rules for cleanliness
  85
• 1.5 Removing and installing fuel cooler
  85
• 1.6 Removing and installing fuel tank
  86
• 1.7 Repairing throttle mechanism
  88
• 1.8 Checking accelerator position sender G79
  90
• 1.9 Adjusting accelerator position sender G79
  94
• 1.10 Checking tandem pump
  95
• 1.11 Removing and installing tandem pump
  97
• Turbocharging/supercharging
  100
• 1 Charge air system with turbocharger
  100
• 1.1 Safety precautions
  100
• 1.2 Rules for cleanliness
  100
• 1.3 Removing and installing turbocharger with attachments
  100
• 1.4 Removing and installing parts of charge air cooling
  103
• 1.5 Charge pressure control hose routing diagram
  104
• 2 Checking charge pressure control
  105
• 2.1 Checking charge pressure control solenoid valve N75
  107
• Mixture preparation - injection
  109
• 1 Repairing diesel direct injection system
  109
• 1.1 Safety precautions
  109
• 1.2 Rules for cleanliness
  110
• 1.3 Overview of fitting locations
  110
• 1.4 Repairing intake manifold flap
  111
• 1.5 Repairing unit injector
  113
• 1.6 Removing and installing O-rings for unit injector
  113
• 1.7 Removing and installing unit injector
  115
• 2 Checking components and functions
  121
• 2.1 Checking voltage supply for diesel direct injection system
  121
• 2.2 Checking engine speed sender G28
  121
• 2.3 Checking intake manifold pressure sender G71 and altitude sender F96
  122
• 2.4 Checking coolant temperature sender G62
  124
• 2.5 Checking brake light switch F and brake pedal switch F47
  126
• 2.6 Checking clutch pedal switch F36
  127
• 2.7 Checking intake manifold temperature sender G72
  129
• 2.8 Checking fuel temperature sender G81
  130
• 2.9 Checking air mass meter G70
  132
• 2.10 Checking intake manifold flap change-over
  134
• 2.11 Checking intake manifold flap motor V157
  136
• 2.12 Checking unit injector valves
  137
• 2.13 Checking camshaft position Hall sender G40
  139
• 3 Checking additional signals
  141
• 3.1 Checking speed signal
  141
• 3.2 Checking signal from/to air conditioning system
  142
• 3.3 Checking speed signal
  145
• 3.4 Checking cruise control system (CCS)
  145
• 3.5 Checking data bus
  147
• 4 Renewing, coding and adapting engine control unit
  153
• 4.1 Renewing engine control unit
  153
• 4.2 Coding engine control unit
  153
• 4.3 Adapting engine control unit to electronic immobilizer
  154
• Exhaust system
  156
• 1 Removing and installing parts of exhaust system
  156
• 1.1 Front exhaust pipe with catalytic converters and attachments
  156
• 1.2 Silencer with mountings
  157
• 2 Exhaust gas recirculation system
  158
• 2.1 Removing and installing parts of exhaust gas recirculation system
  158
• 2.2 Schematic diagram for vacuum hoses
  160
• 2.3 Checking exhaust gas recirculation valve
  160
• 2.4 Checking exhaust gas recirculation
  161
• Glow plug system
  165
• 1 Checking glow plug system
  165
• 1.1 Checking glow plugs
  166