Table of contents Page
Specifications ............................................................................................................................... 9
Service data.................................................................................................................................10
Tightening torque values...............................................................................................................24
Turbocharger, troubleshooting......................................................................................................28
View of engine D 0836 LE 501......................................................................................................30
Checking compression .................................................................................................................31
Checking valve timing...................................................................................................................32
Setting valve clearance.................................................................................................................33
Reassembling and refitting intake pipe...........................................................................................35
Removing and refitting turbocharger..............................................................................................36
Removing and refitting manifold....................................................................................................38
Removing and refitting cylinder head.............................................................................................39
Dismantling and reassembling the rocker arm assembly.................................................................43
Removing and refitting valves .......................................................................................................45
Removing and refitting valve guides ..............................................................................................48
Replacing valve seat insert ...........................................................................................................49
Re-machining the valve seat.........................................................................................................51
Reseating valves..........................................................................................................................54
Replacing engine coolant..............................................................................................................55
Removing and refitting the thermostatic valve ................................................................................57
Removing and refitting water pump...............................................................................................58
Removing and refitting coolant pipe...............................................................................................62
Layout of fuel system ...................................................................................................................63
Fuel pre filter / Cartridge...............................................................................................................64
Purging Air from Fuel Supply System............................................................................................66
Removing and refitting heater plug................................................................................................67
Power - belts ...............................................................................................................................68
Removing and refitting the starter engine.......................................................................................71
Removing and refitting generator...................................................................................................72
Removing and refitting air compressor...........................................................................................74
Replacing crankshaft front seal .....................................................................................................79
Removing and refitting flywheel.....................................................................................................80
Removing and refitting crankshaft seal (flywheel)...........................................................................82
Removing and refitting flywheel.....................................................................................................83
Removing and refitting the timing case..........................................................................................85
Removing and refitting camshaft ...................................................................................................89
Removing and refitting intermediate flange....................................................................................91
Removing and refitting the con-rod bearing shells ..........................................................................92
Removing and refitting the crankshaft............................................................................................93
Removing and refitting con-rod......................................................................................................96
Removing and refitting the piston rings ........................................................................................101
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