6-cyl. fuel 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
  2
• 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 Securing engine to engine stand
  6
• 1.4 Notes on installing
  6
• 1.5 Tightening torques
  8
• 1.6 Assembly mountings
  9
• 1.7 Additional information and removal instructions for vehicles with air conditioner
  10
• Crankshaft group
  11
• 1 Dismantling and assembling engine
  11
• 1.1 Dismantling and assembling engine
  11
• 1.2 Removing and installing ribbed belt
  32
• 1.3 Checking valve timing
  33
• 1.4 Adjusting valve timing
  34
• 2 Removing and installing sealing flanges and flywheel/drive plate
  40
• 2.1 Removing and installing sealing flanges and flywheel/drive plate
  40
• 2.2 Renewing crankshaft oil seal - vibration damper end -
  43
• 2.3 Removing and installing dual mass flywheel
  46
• 2.4 Removing and installing drive plate
  47
• 3 Removing and installing crankshaft
  49
• 3.1 Removing and installing crankshaft
  49
• 4 Dismantling and assembling pistons and conrods
  52
• 4.1 Dismantling and assembling pistons and conrods
  52
• 4.2 Piston and cylinder dimensions
  58
• Cylinder head, Valve gear
  59
• 1 Removing and installing cylinder head
  59
• 1.1 Removing and installing cylinder head
  59
• 1.2 Removing and installing cylinder head cover
  67
• 1.3 Installing cylinder head
  72
• 1.4 Checking compressions
  73
• 2 Servicing valve gear
  75
• 2.1 Servicing valve gear
  75
• 2.2 Reworking valve seats
  81
• 2.3 Removing and installing camshafts
  83
• 2.4 Checking hydraulic bucket tappets
  86
• 2.5 Checking valve guides
  87
• 2.6 Renewing valve guides
  88
• 2.7 Renewing valve stem seals
  89
• Lubrication
  90
• 1 Removing and installing parts of the lubrication system
  90
• 1.1 Removing and installing parts of the lubrication system
  90
• 1.2 Dismantling and assembling oil filter housing
  96
• 1.3 Dismantling and assembling oil pump
  99
• 1.4 Checking oil pressure and oil pressure switch
  102
• Cooling system
  104
• 1 Removing and installing parts of cooling system
  104
• 1.1 Removing and installing parts of cooling system
  104
• 1.2 Parts of cooling system body side
  105
• 1.3 Parts of cooling system engine side
  109
• 1.4 Coolant hose connection diagram
  113
• 1.5 Dismantling and assembling coolant thermostat housing
  115
• 1.6 Draining and filling cooling system
  117
• 1.7 Removing and installing radiator and radiator fan
  119
• 1.8 Removing and installing coolant pump
  121
• 1.9 Checking thermo switch and continued coolant circulation pump
  121
• 1.10 Checking vacuum valve
  123
• Fuel supply system
  125
• 1 Removing and installing parts of fuel supply system
  125
• 1.1 Removing and installing parts of fuel supply system
  125
• 1.2 Removing and installing fuel tank with its attachments and fuel filter
  126
• 1.3 Safety precautions when working on the fuel supply system
  132
• 1.4 Rules for cleanliness
  132
• 1.5 Removing and installing fuel delivery unit
  132
• 1.6 Removing and installing fuel tank
  134
• 1.7 Checking fuel pump
  135
• 1.8 Servicing accelerator mechanism
  141
• 1.9 Adjusting throttle cable
  143
• 1.10 Servicing parts of the activated charcoal filter system
  145
• Exhaust system
  147
• 1 Removing and installing parts of exhaust system
  147
• 1.1 Removing and installing parts of exhaust system
  147
• 1.2 Exhaust manifold, front exhaust pipe and catalyst with attachments
  147
• 1.3 Silencer with mountings
  152
• 2 Exhaust gas recirculation system
  153
• 2.1 Exhaust gas recirculation system
  153
• 2.2 Checking exhaust gas recirculation valve
  156
• 3 Secondary air system
  158
• 3.1 Secondary air system
  158
• 3.2 Function
  158
• 3.3 Removing and installing parts of the secondary air system
  159
• 3.4 Checking combi-valve
  163
• 3.5 Removing and installing combi-valve
  164