Engine Ch 1 page Chapter 1 Engine Index Removal of engine assembly................................................................. 5 Lifting the engine.........................................................................................................................11 Engine identification............................................................................ 12 Fuel system...........................................................................................
13 Schematic diagram of the fuel system.........................................................................................13 Overflow valve..............................................................................................................................13 General........................................................................................................................................14 FUEL............................................................................................................................................14 Fuel filter......................................................................................................................................15 Water separating prefilter.............................................................................................................15 Feed pump...................................................................................................................................17 Diagnostic prosedure...........................................................................
18 Use of diagnostic kit, machine 810001 - 810052.......................................................................18 Use of diagnostic kit, machine 810053 - ....................................................................................20 Measurement...............................................................................................................................23 Ecom standard settings code......................................................................................................26 Engine control unit, ECU......................................................................
29 Wiring and cable duct..................................................................................................................30 Throttle position sensor...............................................................................................................30 Positions of sensors for ECU.......................................................................................................31 Diagnostic lamp and switch (810001 - 810035)...........................................................................32 Diagnostic lamp and switch (810036 - ).......................................................................................33 Fault codes..................................................................................................................................34 How to read fault codes from the ECU control unit......................................................................35 Flash codes tables.......................................................................................................................37 Overview of flash codes for coordinator.......................................................................................39 Renewing the control unit............................................................................................................41 Removing the ECU wiring...........................................................................................................42 Cylinder head........................................................................................
46 Special tools................................................................................................................................46 Cylinder head, parts view.............................................................................................................47 Valve mechanism.........................................................................................................................48 Dismantling .................................................................................................................................53 Renewing the valve stem seal.....................................................................................................53 Replacement of valve seats.........................................................................................................54 Machining the valve seats insert..................................................................................................55 Renewing the valve guides.........................................................................................................57 Renewing PDE unit injector sleeves............................................................................................58 Assembly ....................................................................................................................................59 Fitting...........................................................................................................................................59 PDE Injectors.........................................................................................
60 Fitting the PDE injector................................................................................................................60 Adjusting unit injectors.................................................................................................................64 Adjusting the valve clearance and unit injectors..........................................................................66 Checking, adjusting the PDE injector rocker arms.......................................................................67 Turbocharger.........................................................................................
69 General .......................................................................................................................................70 Special tools................................................................................................................................71 Measuring radial clearance and axial clearance .........................................................................72 Renewing the turbocharger.........................................................................................................74 Continuation next page SHOP MANUAL MT41 - 12.2004