Technical data
11 Technical data
11.1 Engine number
11.2 Engine data
1Removing and installing engine
21 Removing and installing engine
21.1 Removing engine
21.2 Securing engine to assembly stand
71.3 Notes on installing
81.4 Assembly mountings
11Crankshaft group
121 Dismantling and assembling engine
121.1 Assembly overview - toothed belt drive
121.2 Assembly overview - poly V-belt drive
141.3 Removing and installing poly V-belt
141.4 Assembly overview - crankcase
162 Removing and installing sealing flange and flywheel
192.1 Assembly overview - sealing flange and flywheel
192.2 Renewing crankshaft oil seal - pulley end
202.3 Removing and installing sealing flange - pulley end
222.4 Renewing crankshaft sealing flange - flywheel end
243 Crankshaft
333.1 Assembly overview - crankshaft
333.2 Crankshaft dimensions
343.3 Pulling needle bearing out of and driving into crankshaft
344 Pistons and conrods
364.1 Assembly overview - pistons and conrods
364.2 Separating new conrods
374.3 Checking piston projection at TDC
384.4 Piston and cylinder dimensions
394.5 Piston rings, cylinder bore and piston installation position
39Cylinder head, valve gear
421 Cylinder head
421.1 Assembly overview - cylinder head
421.2 Removing and installing cylinder head cover
451.3 Removing, installing and tensioning toothed belt
461.4 Removing and installing cylinder head
531.5 Checking compression
572 Repairing valve gear
592.1 Assembly overview - valve gear
592.2 Checking valve guides
612.3 Renewing valve stem seals
622.4 Removing and installing camshaft
642.5 Removing and installing camshaft oil seal
68Lubrication
711 Engine oil
711.1 Oil capacities
711.2 Engine oil specifications
711.3 Checking engine oil level
712 Parts of lubrication system
722.1 Assembly overview - oil pump, sump
722.2 Removing and installing oil sump
733 Oil filter bracket, oil pressure and oil cooler
763.1 Assembly overview - oil filter bracket and oil cooler
763.2 Checking oil pressure and oil pressure switch
77Cooling
791 Parts of cooling system
791.1 Parts of cooling system, body side
791.2 Parts of cooling system - engine side
811.3 Coolant hose schematic diagram
831.4 Draining and filling coolant
841.5 Removing and installing fan mounting with fans
881.6 Removing and installing radiator
891.7 Removing and installing coolant pump
911.8 Removing and installing thermostat
921.9 Checking cooling system for leaks
941.10 Checking oil cooler for leaks
96Fuel supply system
991 Safety precautions when working on fuel supply system
992 Rules for cleanliness
1003 Fuel tank
1013.1 Assembly overview - fuel tank
1013.2 Emptying fuel tank
1033.3 Removing and installing fuel tank
1053.4 Removing and installing fuel delivery unit
1073.5 Removing and installing fuel gauge sender G
1093.6 Checking fuel pump
1094 Repairing fuel supply system
1124.1 Assembly overview - fuel filter
1124.2 Removing and installing fuel cooler
1134.3 Checking tandem pump
1144.4 Removing and installing tandem pump
1184.5 Assembly overview - accelerator mechanism
121Turbocharging/supercharging
1231 Charge air system with turbocharger
1231.1 Safety precautions
1231.2 Rules for cleanliness
1231.3 Assembly of hose connections
1241.4 Assembly overview - turbocharger
1251.5 Removing and installing turbocharger
1271.6 Assembly overview - charge air cooling
1281.7 Checking charge air system for leaks
129Mixture preparation - injection
1321 Repairing diesel direct injection system
1321.1 Safety precautions
1321.2 Rules for cleanliness
1331.3 Assembly overview - unit injector
1331.4 Removing and installing O-rings for unit injector
1341.5 Removing and installing unit injector
1351.6 Assembly overview - intake manifold with intake manifold flap
1381.7 Assembly overview - air filter
1402 Engine control unit
1412.1 Reading and erasing engine control unit fault memory
1412.2 Adapting functions and components
1422.3 Removing and installing anti-theft engine control unit
1432.4 Removing and installing engine control unit
146Exhaust system
1471 Parts of the exhaust system
1471.1 Assembly overview - front exhaust pipe with particulate filter
1471.2 Assembly overview - silencers with mountings
1491.3 Aligning exhaust system free of stress
1502 Exhaust gas recirculation system
1512.1 Assembly overview - exhaust gas recirculation
1512.2 Assembly overview - exhaust gas recirculation cooler
1522.3 Vacuum hose schematic diagram
153Glow plug system
1541 Checking glow plug system
1541.1 Characteristics of ceramic glow plugs
1541.2 Removing, installing and checking ceramic glow pin plugs
154