6-Cyl. injection engine Mechanics

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
  3
• 1.3 Notes on installing
  6
• 1.4 Tightening torques
  7
• 1.5 Assembly mountings
  8
• 1.6 Aligning engine and gearbox
  9
• 1.7 Renewing engine carrier rubber mounting
  10
• 1.8 Additional information and removal instructions for vehicles with air conditioner
  10
• Crankshaft group
  12
• 1 Dismantling and assembling engine
  12
• 1.1 Dismantling and assembling engine
  12
• 1.2 Removing and installing ribbed belt
  31
• 1.3 Checking valve timing
  32
• 1.4 Adjusting valve timing
  33
• 2 Removing and installing sealing flanges and flywheel/drive plate
  39
• 2.1 Removing and installing sealing flanges and flywheel/drive plate
  39
• 2.2 Renewing crankshaft oil seal - vibration damper end -
  41
• 2.3 Removing and installing drive plate
  43
• 3 Removing and installing crankshaft
  45
• 3.1 Removing and installing crankshaft
  45
• 4 Dismantling and assembling pistons and conrods
  48
• 4.1 Dismantling and assembling pistons and conrods
  48
• 4.2 Piston and cylinder dimensions
  54
• Cylinder head, Valve gear
  55
• 1 Removing and installing cylinder head
  55
• 1.1 Removing and installing cylinder head
  55
• 1.2 Removing and installing cylinder head cover
  62
• 1.3 Installing cylinder head
  64
• 1.4 Checking compressions
  65
• 2 Servicing valve gear
  66
• 2.1 Servicing valve gear
  66
• 2.2 Reworking valve seats
  72
• 2.3 Removing and installing camshafts
  73
• 2.4 Checking hydraulic bucket tappets
  76
• 2.5 Checking valve guides
  77
• 2.6 Renewing valve guides
  77
• 2.7 Renewing valve stem seals
  78
• Lubrication
  80
• 1 Removing and installing parts of the lubrication system
  80
• 1.1 Removing and installing parts of the lubrication system
  80
• 1.2 Dismantling and assembling oil filter housing
  86
• 1.3 Dismantling and assembling oil pump
  89
• 1.4 Checking oil pressure and oil pressure switch
  92
• Cooling system
  93
• 1 Removing and installing parts of cooling system
  93
• 1.1 Removing and installing parts of cooling system
  93
• 1.2 Parts of cooling system body side
  94
• 1.3 Parts of cooling system engine side
  97
• 1.4 Dismantling and assembling coolant thermostat housing
  101
• 1.5 Draining and filling cooling system
  104
• 1.6 Removing and installing radiator and radiator fan
  106
• 1.7 Removing and installing coolant pump
  107
• 1.8 Checking coolant continued circulation pump and radiator fan run-on
  109
• Fuel supply system
  110
• 1 Removing and installing parts of fuel supply system
  110
• 1.1 Removing and installing parts of fuel supply system
  110
• 1.2 Removing and installing fuel tank with attachments and fuel filter
  111
• 1.3 Safety precautions when working on the fuel supply system
  116
• 1.4 Rules for cleanliness
  116
• 1.5 Adjusting throttle cable
  117
• 1.6 Removing and installing fuel delivery unit
  119
• 1.7 Checking fuel pump
  120
• 1.8 Removing and installing parts of the activated charcoal filter system
  124
• 1.9 Checking fuel tank breather
  126
• Exhaust system
  128
• 1 Removing and installing parts of exhaust system
  128
• 1.1 Removing and installing parts of exhaust system
  128
• 1.2 Exhaust manifold, front exhaust pipe and catalyst with attachments
  129
• 1.3 Silencer with mountings
  131
• 2 Exhaust gas recirculation system
  132
• 2.1 Exhaust gas recirculation system
  132
• 2.2 Checking exhaust gas recirculation valve with temperature sensor
  134
• 3 Secondary air system
  136
• 3.1 Secondary air system
  136
• 3.2 Function
  136
• 3.3 Removing and installing parts of the secondary air system
  137
• 3.4 Checking combi-valve
  140
• 3.5 Checking secondary air pump motor
  140
• 3.6 Checking change-over valve
  141
• 3.7 Removing and installing combi-valve and secondary air pump motor
  142