Engine number Engine number ("engine code" and "serial number") located at the junction of the engine / gearbox - see. arrow-. In addition, there is a sticker on the toothed belt guard with "engine code" and "serial number of the...
Removing and installing the engine cover Carefully! When removing and installing the engine cover, if necessary, avoid impacts and accidental contact with the fuel return line or wiring. Otherwise, a break in the terminals on the injectors may occur. As a...
Removing the engine Note: If the engine block was replaced when the engine was removed, then tighten the injector pressure plates to the specified torque when installing the new engine block. The engine is removed together with the gearbox...
Engine installation Note: Replace screws that are tightened to the specified angle. Replace self-locking nuts and screws, as well as O-rings and gaskets. Fittings, as well as air ducts and hoses must be degreased before installation. To...
Details and assemblies of the supports of the power unit 1. Bolt: replace after disassembly 2. Engine mount bracket 3. Motor support: with bracket 4. 40 Nm and tighten by 90° (¼ vol.): replace after disassembly 5. 20 Nm and tighten by 90° (¼ vol.): replace after disassembly...
Engine Mount Bracket — Torque and Tightening Order Note: Replace bolts that are tightened further to the specified angle. Tighten the bolts step by step in the sequence shown. Installation of the lower support of the power unit Note: Replace screws that are tightened to...
Removal and installation of engine mounts Remove engine cover. Detach hose -1- for crankcase breather from cylinder head cover by pressing hose clips. Unclip vacuum hoses -arrows- at breather pipe. Loosen clamp -3-, detach air duct from mass air flow meter...
Power unit mount adjustment Hang the motor in the mounting position. Slightly tighten power unit with spindle -MP9 -200/10-, but do not lift. Unscrew bolts -arrows- for engine mounting one by one and replace them if this was not done when...
Details and knots of transmission poly V-belt 1. V-ribbed belt: check the degree of wear; before removing, mark the direction of the belt with chalk or a felt-tip pen; do not bend; during installation, ensure the correct position on the pulleys 2. 10 Nm and tighten...
Removal and installation of poly V-belt Remove soundproofing. Carefully! Risk of destruction of an already used V-ribbed belt when it is installed in the opposite direction. If the replacement of the V-ribbed belt is not planned, then before removing it, the...
Removal and installation of the crankshaft pulley Remove poly V-belt. Loosen the crankshaft pulley bolts; to do this, use a spanner wrench to hold the crankshaft from turning by the toothed pulley bolt. Unscrew the bolts and remove the crankshaft pulley. Installation...
Removal and installation of a poly V-belt tensioner Remove poly V-belt. Unscrew bolts -arrows- and remove poly V-belt tensioner. Installation Installation in reverse order. Note: Replace bolts that are tightened further to the specified angle. Install poly V-belt.
Removal and installation of an arm of hinged units Remove generator. Remove HPV. Loosen nut -2- and screw -1-, press front right coolant pipe slightly forward. Remove bracket -1- with fuel hoses. Remove screws -arrows-. -Position 2, 3- ignore. Remove bolts -arrows- and...
Parts and assemblies of the toothed belt guard 1. Lower part of the toothed belt cover 2. 12 Nm: with collar; inserted into the bottom of the toothed belt housing so that it is not lost 3. 5 Nm 4. Line: to differential pressure sender -G505- 5. Upper timing belt...
Parts and assemblies of toothed belt drive 1. 180 Nm and turn by 135°: turn can be done in several steps, eg 90°+ 45°; replace after disassembly; unscrew and tighten with stop -T30004 (3415) -; additional lubrication of the thread and shoulder is not necessary...
Removal and installation of the bottom part of a casing of a gear belt Note: To simplify the assembly process in production plants, the lower part of the toothed belt guard is provided with a guide that grips the crankshaft cover. To remove the lower part of the toothed belt guard with the...
Removal and installation of a gear belt Remove engine mount bracket. Remove the top part of the toothed belt guard. Remove the bottom part of the toothed belt guard. Attention! Risk of destruction of valves and pistons when the toothed belt jumps. Rotate the...
Installing / adjusting the timing Note: To carry out adjustment work on the toothed belt, the engine must be cold. Attention! Risk of damage to valves and piston crowns. When turning the camshaft, no piston should be in the "TDC" position". Conditions...
Checking the installation of the timing phases Attention! Danger of destroying the engine when the toothed belt jumps. Rotate the crankshaft only in the direction of engine rotation. By rotating the crankshaft by the bolt of the toothed pulley 2 in the direction of...
Removing and installing the crankshaft cover on the pulley side Remove the front right fender liner. Remove toothed belt. Remove crankshaft sprocket. To do this, hold the pulley with the stop -T30004 (3415) - or stop -MP 1-310-. Remove oil pan. Unscrew the remaining screws and...
Removing and installing the crankshaft cover on the gearbox side Pressing out the cover with the master rotor CP removed. Remove flywheel. Instruction. For a better idea, the procedure is shown with the engine removed. Remove intermediate plate from crankshaft rear cover and dowel...
Removal and installation of a flywheel CP removed. Attention! Risk of damage to the flywheel. Remove bolts -B- using hand tools only. Do not use pneumatic or impact wrenches. When unscrewing the bolts, make sure that their heads do not touch the flywheel....
Details and assemblies of the cylinder head cover Note: Cylinder heads with cracks between the valve seats can continue to be used, without reducing the engine life, if the width of the cracks does not exceed 0.5 mm. Milling of the cylinder head of diesel engines is...
Removal and installation of cylinder head cover Note: When carrying out work, reinstall all heat shields. Remove the top engine cover. Unscrew flue gas temperature sender 3 -C495- -pos. 2- with the tool from the 17 mm tool set -T10395- and a suitable socket. Unscrew...
Parts and assemblies: cylinder head 1. Cylinder block 2. Cylinder head gasket; after replacement, replace the coolant and oil in the engine; consider catalog number 3. Cylinder head: place the removed cylinder head only on a foam pad, otherwise the glow...
Removing the cylinder head The engine temperature should not be higher than 35°C, otherwise the cylinder head may warp when the screws are unscrewed. The pistons must not be at TDC. Carefully! When performing installation work, especially in the...
Installing the cylinder head Note: The threaded holes of the cylinder head bolts in the cylinder block must be free of oil or coolant. Replace cylinder head screws. Do not reuse self-locking nuts. Replace screws that are tightened to a certain...
Compression test The engine oil temperature is about 80°C. The battery voltage is not lower than 12.5 V. Remove the upper engine cover. Unplug electrical connector at fuel pressure regulator -N276- -pos. 2-. -Position 1- ignore. To...
Details and components of the gas distribution mechanism 1. Valve: not subject to processing, only grinding is allowed; mark installation position for reinstallation 2. Cylinder head: due to small tolerances, modification of the valve seats is prohibited. 3. Mounting pin:...
Removal and installation of the camshaft housing The cylinder head is installed. Remove toothed belt from camshaft. Remove cylinder head cover. Remove fuel rail. Remove left coolant pipes. Unscrew bolts -arrows-, push fuel lines slightly forward. Unplug connector -2-...
Checking hydraulic lifters Note: Hydraulic expansion joints cannot be repaired. Irregular valve tapping when starting the engine is not a malfunction. Start the engine and let it run until the radiator fan turns on. Increase engine speed to...
Lubrication system — design description 1. 8 Nm: self-locking; replace after disassembly 2. Oil level and oil temperature sender -G266- 3. O-ring: replace after disassembly 4. Oil drain plug, 30 Nm: with integral O-ring; replacement 5. O-ring: part of the...
Removing and installing oil level and oil temperature sender -G266- Drain engine oil. Disconnect electrical connector -arrow- from oil level and oil temperature sender -G266-. Loosen fasteners -arrows- and remove noise insulation -1- from oil sump. Remove screws -1- and remove oil level...
Parts and assemblies of the oil filter bracket 1. Oil drain plug, 5 Nm 2. O-ring: replace after disassembly 3. Cover, 25 Nm 4. O-ring: replace after disassembly; lubricate with engine oil 5. Filter element 6. O-ring: non-removable, if the oil pressure sensor is...
Removing and installing oil filter bracket with oil cooler Note: The engine oil cooler must not be disconnected from the oil filter housing. In the event of a malfunction, the engine oil cooler is replaced along with the oil filter bracket. Remove air filter. Remove the frame...
Removal and installation of the oil pallet Drain engine oil. Disconnect electrical connector -arrow- from oil level and oil temperature sender -G266-. Loosen fasteners -arrows- and remove noise insulation -1- from sump. Remove bolts -arrows- for oil...
Removal and installation of the oil pump Remove oil pan. Carefully! Avoid kinking, twisting or damage to the toothed belt on sharp edges! Remove screws -arrows- and remove oil pump -1-. Carefully! Do not unscrew or loosen the pump gear screw. Installation...
Removing and installing oil pressure switch -F1- Remove the top engine cover. Unscrew bolts -1, 3-. Release catch -arrow- and remove cover -2-. Release coolant hose -2-. Unlock retainers -arrows- and remove top section of air duct -1-. Unscrew left and right screws...
Removing and installing oil pressure control valve N428- Remove poly V-belt. Detach the air conditioner compressor with hoses connected from the bracket and hang it on the right side. Disconnect connector -1-. Remove screw -2- and remove oil pressure control valve -N428-....