5-cylinder diesel engine

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Engine number
  1
• 1.2 Engine data
  1
• Self-diagnosis
  3
• 1 Self-diagnosis
  3
• 1.1 Features of self-diagnosis
  3
• 1.2 Technical data of self-diagnosis
  3
• 1.3 Connecting vehicle diagnosis, testing and information system VAS 5051
  4
• 2 Fault memory
  6
• 2.1 Reading and erasing fault memory
  6
• 3 Fault table: V.A.G codes
  7
• 4 Fault table: SAE P codes
  17
• 5 Final control diagnosis
  30
• 5.1 Performing final control diagnosis
  30
• 6 Measured value blocks
  33
• 6.1 Safety precautions
  33
• 6.2 Read measured value block
  33
• 6.5 Evaluating read measured value blocks at idling speed, engine code AGX
  49
• 6.6 Evaluating read measured value blocks at full throttle, engine code AGX
  57
• Removing and installing engine
  61
• 1 Removing and installing engine
  61
• 1.1 Removing engine
  61
• 1.2 Securing engine on engine and gearbox support
  66
• 1.3 Installing engine
  66
• 1.4 Additional information and assembly work for vehicles with air conditioner
  68
• Crankshaft group
  70
• 1 Dismantling and assembling engine
  70
• 1.1 Overview
  70
• 1.2 Removing and installing poly-V belt
  76
• 1.3 Removing and installing tensioner for poly V-belt
  77
• 2 Removing and installing sealing flange and flywheel
  78
• 2.1 Renewing crankshaft oil seal - pulley end
  79
• 3 Removing and installing crankshaft
  82
• 3.1 Crankshaft dimensions
  83
• 3.2 Pulling needle roller bearing out of and driving into crankshaft
  83
• 4 Dismantling and assembling pistons and conrods
  85
• 4.1 Checking piston projection at TDC
  87
• 4.2 Piston and cylinder dimensions
  89
• Cylinder head, valve gear
  90
• 1 Removing and installing cylinder head
  90
• 1.1 Installing cylinder head
  92
• 1.2 Removing and installing camshaft toothed belt
  94
• 1.3 Checking compression
  99
• 2 Repairing valve gear
  102
• 2.1 Reworking valve seats
  104
• 2.2 Checking valve guides
  105
• 2.3 Renewing valve guides
  106
• 2.4 Renewing valve stem seals
  107
• 2.5 Removing and installing camshaft
  109
• 2.6 Checking hydraulic bucket tappets
  110
• Lubrication
  112
• 1 Removing and installing parts of lubrication system
  112
• 1.1 Engine oil:
  112
• 1.2 Overview
  112
• 1.3 Checking oil pressure and oil pressure switch
  117
• Cooling
  119
• 1 Removing and installing parts of cooling system
  119
• 1.1 Parts of cooling system, body side
  119
• 1.2 Parts of cooling system - engine side
  121
• 1.3 Coolant hose schematic diagram
  123
• 1.4 Draining and adding coolant
  124
• 1.5 Removing and installing radiator
  126
• 1.6 Removing and installing viscous fan coupling
  128
• Fuel supply system
  131
• 1 Removing and installing parts of fuel supply system
  131
• 1.1 Removing and installing fuel tank with attached components
  131
• 1.2 Repairing fuel filter
  132
• 1.3 Safety measures when working on fuel supply
  133
• 1.4 Rules for cleanliness
  133
• 1.5 Emptying fuel tank
  134
• 1.6 Removing and installing fuel tank
  134
• 1.7 Removing and installing fuel delivery unit
  137
• 1.8 Repairing accelerator mechanism
  138
• 1.9 Checking adjustment of accelerator position sender
  139
• 1.10 Checking accelerator position sender
  140
• Turbocharging/supercharging
  143
• 1 Charge air system with turbocharger
  143
• 1.1 Removing and installing turbocharger with attachments
  143
• 1.2 Removing and installing parts of charge air cooling
  147
• 1.3 Removing and installing turbocharger
  148
• 2 Checking charge pressure system
  152
• 2.1 Checking charge pressure control
  152
• Mixture preparation - injection
  157
• 1 Repairing diesel direct injection system
  157
• 1.1 Safety precautions
  157
• 1.2 Rules for cleanliness
  158
• 1.3 Overview of fitting locations
  158
• 1.4 Removing and installing injection pump toothed belt
  160
• 1.5 Repairing injection pump
  160
• 1.6 Repairing intake manifold flap
  162
• 1.7 Removing, installing and tensioning injection pump toothed belt
  164
• 1.8 Removing and installing injection pump
  167
• 1.9 Dynamically checking and adjusting commencement of injection
  170
• 1.10 Removing and installing injectors
  173
• 1.11 Repairing injectors
  174
• 1.12 Renewing injection timing device cover O-ring
  175
• 2 Checking components and functions
  176
• 2.1 Connecting test box
  176
• 2.2 Checking voltage supply for diesel direct injection system
  177
• 2.3 Checking engine speed sender
  178
• 2.4 Checking intake manifold pressure sender and altitude sender
  179
• 2.5 Checking coolant temperature sender
  182
• 2.6 Checking intake manifold temperature sender
  184
• 2.7 Checking fuel temperature sender
  186
• 2.8 Checking modulating piston movement sender and metering adjuster
  188
• 2.9 Checking needle lift sender
  192
• 2.10 Checking injection timing control range
  194
• 2.11 Checking air mass meter
  198
• 2.12 Checking intake manifold flap changeover
  201
• 3 Checking additional signals
  204
• 3.1 Checking speed signal
  204
• 3.2 Checking signals from and to air conditioning system
  205
• 3.3 Checking speed signal
  206
• 3.4 Checking signal from brake light switch and brake pedal switch
  207
• 3.5 Checking signal from clutch pedal switch
  208
• 4 Renewing, coding and matching engine control unit
  210
• 4.1 Renewing engine control unit
  210
• 4.2 Coding engine control unit
  210
• 4.3 Activating maximum speed governor in engine electronics control unit
  211
• 4.4 Activating cruise control system
  213
• Exhaust system
  214
• 1 Removing and installing parts of exhaust system
  214
• 1.1 Overview
  214
• 2 Exhaust gas recirculation system
  219
• 2.1 Removing and installing parts of exhaust gas recirculation system
  219
• 2.2 Vacuum hose schematic diagram
  220
• 2.3 Checking exhaust gas recirculation valve
  221
• 2.4 Checking exhaust gas recirculation system
  222
• Glow plug system
  228
• 1 Glow plug system
  228
• 1.1 Checking glow plug system
  228
• 1.2 Checking glow plugs
  228