5-Cyl. diesel engine, Mech.

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
  8
• 1.4 Notes on installing
  10
• 1.5 Tightening torques
  11
• 1.6 Additional information and work instructions for vehicles with air conditioner
  12
• Crankshaft group
  13
• 1 Dismantling and assembling engine
  13
• 1.1 Dismantling and assembling engine
  13
• 1.2 Adjusting alternator V-belt tension
  35
• 1.3 Removing and installing ribbed belt
  36
• 1.4 Removing and installing ribbed belt tensioning device
  39
• 1.5 Removing, installing and tensioning camshaft toothed belt (>01.95)
  42
• 1.6 Removing, installing and tensioning camshaft toothed belt (02.95 >)
  49
• 1.7 Removing, installing and tensioning injection pump toothed belt (engine codes AAB, AJA)
  55
• 2 Removing and installing sealing flange and flywheel
  66
• 2.1 Removing and installing sealing flange and flywheel
  66
• 2.2 Removing and installing drive plate
  71
• 2.3 Removing and installing dual mass flywheel
  73
• 2.4 Renewing crankshaft oil seal - pulley end -
  74
• 3 Removing and installing crankshaft
  77
• 3.1 Removing and installing crankshaft
  77
• 3.2 Crankshaft dimensions
  79
• 4 Dismantling and assembling pistons and conrods
  80
• 4.1 Dismantling and assembling pistons and conrods
  80
• 4.2 Checking piston projection at TDC
  87
• 4.3 Piston and cylinder dimensions
  89
• Cylinder head, Valve gear
  90
• 1 Removing and installing cylinder head
  90
• 1.1 Removing and installing cylinder head
  90
• 1.2 Removing and installing cylinder head
  99
• 1.3 Checking compression pressures
  101
• 2 Servicing valve gear
  104
• 2.1 Servicing valve gear
  104
• 2.2 Reworking valve seats
  113
• 2.3 Checking valve guides
  115
• 2.4 Renewing valve guides
  115
• 2.5 Renewing valve stem seals
  117
• 2.6 Removing and installing camshaft
  119
• 2.7 Checking hydraulic bucket tappets
  120
• 2.8 Replacing swirl chambers (engine codes AAB, AJA)
  121
• Lubrication
  123
• 1 Removing and installing parts of the lubrication system
  123
• 1.1 Removing and installing parts of the lubrication system
  123
• 1.2 Checking oil pressure and oil pressure switch
  138
• Cooling system
  141
• 1 Removing and installing parts of cooling system
  141
• 1.1 Removing and installing parts of cooling system
  141
• 1.2 Parts of cooling system, body side
  142
• 1.3 Parts of cooling system - engine side
  150
• 1.4 Coolant hose connection diagram
  154
• 1.5 Draining and filling coolant
  158
• 1.6 Removing and installing radiator and fan
  161
• 1.7 Checking thermo switch and coolant circulation pump or continued coolant circulation pump
  164
• Fuel supply system
  167
• 1 Removing and installing parts of fuel supply system
  167
• 1.1 Removing and installing parts of fuel supply system
  167
• 1.2 Removing and installing fuel tank with its attachments
  168
• 1.3 Safety precautions when working on the fuel supply system
  170
• 1.4 Rules for cleanliness
  171
• 1.5 Removing and installing fuel gauge sender
  171
• 1.6 Removing and installing fuel tank
  173
• 1.7 Servicing accelerator mechanism (engine codes AAB, AJA)
  174
• 1.8 Adjusting accelerator cable
  176
• 1.9 Servicing cold start accelerator (CSA) operating cable (engine codes AAB, AJA)
  177
• 1.10 Adjusting CSA operating cable
  178
• Charging
  179
• 1 Charge air system with turbocharger
  179
• 1.1 Charge air system with turbocharger
  179
• 1.2 Removing and installing turbocharger with attachments
  179
• 1.3 Removing and installing air cooling parts
  188
• 1.4 Turbocharger hose/pipe connections
  193
• 1.5 Rules for cleanliness
  194
• 1.6 Removing and installing exhaust turbocharger
  195
• 2 Checking charge pressure system
  199
• 2.1 Checking charge pressure system
  199
• 2.2 Checking turbocharger
  199
• Exhaust system
  205
• 1 Removing and installing parts of exhaust system
  205
• 1.1 Removing and installing parts of exhaust system
  205
• 1.2 Removing and installing clamping springs
  210
• 1.3 Tensioning and relieving tension on clamping springs
  211
• 2 Exhaust gas recirculation system
  214
• 2.1 Exhaust gas recirculation system
  214
• 2.2 Removing and installing parts of exhaust gas recirculation system
  214
• 2.3 Vacuum hose connection diagram
  221
• 2.4 Checking exhaust gas recirculation valve
  223