Contents

Abbreviations

Legend

Maintenance and general inspection and adjustment procedures

• Rules for performing work in the engine compartment
• Checking the condition of the engine oil
• Changing the engine oil
• Replacing the oil filter
• Checking the air filter
• Checking the coolant
• Replacing the coolant
• Replacing the fuel filter
• Removing water from the fuel filter
• Removing air from fuel lines
• Checking the battery condition
• Checking and adjusting drive belts of mounted units
• Checking and adjusting the idle speed
• Checking and adjusting the system for increasing the idle speed when the air conditioner is running
• Checking and adjusting the idle speed increase system during ABS operation (engine 4D56)
• Checking and adjusting the fuel injection advance angle (engine 4D56)
• Checking and adjusting the fuel injection advance angle (4M40 engine)
• Additional checks and adjustments of the injection pump (4M40 engine)
• Compression check
• Checking and adjusting clearances in the engine valve drive
• Checking and adjusting the clearances in the valve drive of the 4M40 engine
• Checking the condition of the timing belts and balancing mechanism (engine 4D56)
• Adjusting the timing belt tension (engine 4D56)
• Adjusting the tension of the balancing mechanism drive belt (engine 4D56)

Engine 4D56 - mechanical part

• General information
• Replacing the timing belt and balancer drive belt
• Replacing oil seals
• Replacing the cylinder head gasket
• Complete engine (without gearbox)
• Engine assembly (with gearbox)
• Timing and balancer drive sprockets
• Rocker axis and camshaft
• Cylinder head, valves and valve springs
• Front cover of timing gears and baseplate mechanism
• Piston and connecting rod
• Crankshaft, flywheel (manual transmission) and torque converter drive plate (automatic transmission)
• Cylinder block

Engine 4M40 - mechanical part

• General information
• Replacing crankshaft oil seals
• Replacing the cylinder head gasket
• Engine assembly
• Cylinder head cover and cylinder head assembly
• Camshaft and valves
• Vacuum pump
• Timing gear cover
• Cam gears and balance shafts
• Piston and connecting rod
• Piston and piston pin
• Flywheel (vehicles with manual transmission)
• Torque converter drive plate (vehicles with automatic transmission)
• Crankshaft and cylinder block

Cooling system

• General information
• Checks and adjustments on the car
• Fan
• Radiator
• Thermostat
• Coolant pump
• Sensor for pointer and coolant temperature switch
• Hoses and tubes of the cooling system

Lubrication system

• General information
• Sensors and valves
• Engine oil cooler 4M40(T)
• Engine oil cooler 4D56(T)
• Oil pan and oil intake
• Oil nozzles
• Oil pump (4M40)
• Oil pump (4D56)

Fuel system

• Checking and adjusting the accelerator pedal cable
• Checking the operation of the injection pump
• Checking and adjusting injectors
• Checking the idle speed increase system
• Fuel injectors
• High pressure fuel pump (4D56)
• High pressure fuel pump (4M40)
• Dismantling the injection pump

Electronic engine control system 4M40

• Electronic diesel engine control system
• Intake system
• Engine - mechanical part

Exhaust gas recirculation system

• General information
• Exhaust gas recirculation system valves and sensors
• Control unit for starting aid system and exhaust gas recirculation (engine 4D56T)
• Control unit for the starting aid system and exhaust gas recirculation (engines 4D56T and 4M40)

Intake, exhaust and turbocharging systems

• About current information
• Checking boost pressure (4D56)
• Checking the exhaust gas bypass valve actuator
• Checking the boost pressure control system (vehicles with electronic boost pressure control)
• Charge air intercooler
• `Intake and exhaust manifolds (vehicles without turbocharger)
• Intake and exhaust manifolds (vehicles with turbocharger)
• Turbocharger

Starting system

• General information
• Checking and adjusting the starter (4D56)
• Starter (4D56)
• Starting assistance system
• Glow plugs

Starting system

• General information
• Precautions
• Checking the generator output voltage drop
• Checking the generator output current
• Checking the regulated voltage
• Generator assembly
• Generator and vacuum pump (4D56)

Technical data