Contents

General provisions

• Warning information
• General information about engines
• Practical recommendations

Engine specifications

• Lubrication
• Tightening torques
• Tool
• Standard tightening torques for bolts and nuts

Complete engine disassembly procedure

• Removing the engine from the vehicle and installing it on the "Universal rack 1000" assembly-disassembly stand
• Removing the oil-liquid heat exchanger
• Removing the electronic control unit (ECU)
• Removing accessory drive belts and tensioners
• Removing the alternator
• Removing the vibration damper (damper)
• Removing the fan drive
• Removing the starter
• Removing the water pump
• Removing the exhaust flap
• Removing heat shields
• Removing the turbocharger
• Removing the exhaust manifold
• Removing the intake manifold
• Removing high pressure pipes
• Removing the centrifugal oil cleaner
• Removing the low pressure tubing
• Removing the fine fuel filter (FTOT)
• Removing the ramp
• Removing the cylinder head
• Removing pushers
• Removing the oil separator impeller cover
• Removing the oil crankcase
• Removing the air compressor
• Removing the front cover (accessory drive gears)
• Removing the fuel pump
• Removing engine harnesses
• Removing the oil pump
• Removing the camshaft
• Removing intermediate gears
• Removing the end sheet
• Removing the camshaft bushings
• Removing the flywheel
• Flywheel housing removal
• Removing the block stiffener
• Removing the piston cooling nozzles
• Removing the connecting rod-piston group
• Removing the crankshaft

Disassembly and assembly of engine units

• Cylinder block
• Dismantling the cylinder block
• Flushing the cylinder block
• Cylinder block monitoring
• Cylinder block assembly
• Flywheel
• Flywheel disassembly
• Flywheel assembly
• Crank mechanism (KShM)
• Disassembly of the connecting rod-piston group
• Control of KShM parts
• Assembling the connecting rod-piston group
• Crankshaft
• Disassembly of the crankshaft
• Crankshaft control
• Crankshaft assembly
• Camshaft
• Dismantling the camshaft
• Control of parts of the gas distribution mechanism
• Camshaft assembly
• Torsional vibration damper (damper)
• Removing the crankshaft damper and pulley from the hub
• Damper control
• Installing the crankshaft damper and pulley on the hub
• Exhaust manifold
• Dismantling the exhaust manifold
• Exhaust manifold assembly
• Air compressor
• Removing the air compressor gear
• Installing the air compressor gear
• Cylinder head
• Dismantling the cylinder head
• Dismantling rocker arms with axle and struts
• Assembly of rocker arms with axle and struts
• Cleaning the cylinder head
• Inspection of the cylinder head and MGR parts
• Cylinder head assembly
• Lubrication system
• Coarse oil filter
• Replacing filter elements
• Centrifugal oil cleaner
• Dismantling the centrifugal oil cleaner
• Assembling the centrifugal oil cleaner
• Cooling system
• Oil-liquid heat exchanger
• Dismantling the oil-liquid heat exchanger
• Cleaning the oil-liquid heat exchanger
• Assembling the oil-liquid heat exchanger
• Oil-liquid heat exchanger control
• Fan drive
• Dismantling the fan drive
• Fan drive assembly
• Water pump
• Dismantling the water pump
• Control
• Water pump assembly
• Fuel injection system
• General provisions
• The principle of operation of the Common Rail System 2
• Specifications
• Fuel system repair
• Fuel pump
• High pressure ramp

Assembling the engine

• Installing the crankshaft
• Installing the connecting rod-piston group
• End sheet installation
• Installing the flywheel housing
• Installing the flywheel housing seal
• Installing the flywheel
• Installing the block stiffener
• Installing the oil pump
• Installation of intermediate gears
• Installing the camshaft
• Installing the fuel pump
• Installing the front cover
• Installing the front crankshaft seal
• Air compressor installation
• Installing the oil crankcase
• Installing the oil separator impeller cover
• Installing pushers
• Installing the cylinder head
• Installing rocker arms with axle and struts assembly
• Adjusting the rocker arms
• Installing engine harnesses
• Installing the cylinder head cover
• Installing the ramp and high pressure pipes
• Installing a fine fuel filter
• Installing low pressure pipes
• Installing a centrifugal oil cleaner
• Intake manifold installation
• Installing the exhaust manifold
• Installing the turbocharger
• Installation of heat shields
• Exhaust flap installation
• Water pump installation
• Starter installation
• Installing the fan drive
• Damper installation
• Installing the generator
• Installing Accessory Drive Belts and Tensioners
• Installing the electronic control unit
• Installing a liquid-oil heat exchanger

Turbocharger

• Problems
• Control by car
• Disassembly-assembly of the turbocharger
• Problems and their possible causes

Engine diagnostics

• Short description
• Instrument functions and technical data
• Computer requirements
• Fault codes

Applications

• Appendix A. Symbols
• Appendix B. Tightening torques
• Appendix B. Dimensions and Tolerances
• Appendix D. Tool List
• Appendix E. Parts not to be reinstalled