This book provides only a description of the repair of the engine D4D700 / D4F740 / D4F784 / D4F786 / D4F764 / D4F712 / D4F742 / K4J780 / K4J712 / K4J715 / K9K752 / K9K740 / K9K752 / K9K718 / K9

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Content

In-engine repair procedures - 1.2l gasoline engines

• General information
• Compression test - description and explanation
• Determination of the top dead center for the piston of cylinder no. 1
• Valve clearance - adjustment
• Crankshaft pulley - removal and installation
• Timing belt covers - removal and installation
• Timing belt - removal, inspection, installation and adjustment
• Timing belt tensioner and sprocket - removal, inspection and installation
• Camshaft oil seal - replacement
• Camshaft - removal, inspection and installation
• Cylinder head - removal and installation
• Oil pan and oil pressure pipe - removal and installation
• Oil pump - removal and installation
• Oil pump - disassembly, inspection and assembly
• Crankshaft oil seals - replacement
• Flywheel - removal, inspection and installation
• Engine/gearbox mounts - inspection, removal and installation

In-engine repair procedures - 1.4l and 1.6l gasoline engines

• General Information
• Compression test - description and explanation
• Determination of the top dead center for the piston of cylinder no. 1
• Timing belt - removal, inspection and installation
• Sprockets and timing belt tensioner - removal, inspection and installation
• Camshaft oil seal - replacement
• Camshafts - removal, inspection and installation
• Cylinder head - removal, inspection and installation
• Oil pan - removal and installation
• Oil pump and sprockets - removal, inspection and installation
• Crankshaft oil seals - replacement
• Engine/Gearbox Mounts - Inspection and Replacement
• Flywheel / clutch disc - removal, inspection and installation

In-engine repair procedures - diesel engines

• General Information
• Compression test and leak test - description and explanation
• Engine assembly / valve timing holes - general information and use
• Valve clearance - checking and adjusting
• Timing belt - removal, inspection and installation
• Sprockets, idler pulley and timing belt tensioner - removal and installation
• Camshaft seals - replacement
• Camshaft and tappets - removal, inspection and installation
• Cylinder head - removal, inspection and installation
• Oil pan - removal and installation
• Oil pump and sprockets - removal, inspection and installation
• Crankshaft oil seals - replacement
• Flywheel - removal, inspection and installation
• Engine mounts - replacement

Engine bay removal and overhaul procedures

• General information
• Engine overhaul - general information
• Engine removal - methods and precautions
• Engine - removal and installation
• Engine overhaul - disassembly sequence
• Cylinder head - disassembly
• Cylinder head and valves - cleaning and checking
• Cylinder head - assembly
• Piston / connecting rod assembly - removal
• Crankshaft - removal
• Cylinder block/crankcase - cleaning and checking
• Piston / connecting rod assembly - check
• Crankshaft - check
• Main bearings and connecting rod shells - check
• Engine overhaul - assembly sequence
• Crankshaft - installation
• Piston / connecting rod assembly - installation
• The engine - the start of movement after a major overhaul

Power supply and exhaust system - gasoline engines

• General information and precautions
• Air filter assembly and air ducts - removal and installation
• Accelerator pedal - removal and installation
• Unleaded fuel - general information and use
• Fuel injection system - general information
• Fuel injection system - pressure relief
• Fuel pump - removal and installation
• Fuel level transmitter and pressure regulator - checking, removing and installing
• Fuel tank - removal and installation
• Throttle body - removal and installation
• Fuel injection system - check and adjustment
• Distributed system components about fuel injection - removal and installation
• Collectors - removal and installation
• Turbocharger - removal and installation
• Exhaust system - general information, removal and installation

Power and exhaust system - diesel engines

• General information
• Air filter assembly - removal and installation
• Fuel level transmitter - removal, inspection and installation
• Fuel tank - removal and installation
• Fuel injection system - refueling and bleeding
• Idle speed - general information
• Accelerator pedal - removal and installation
• Electronic engine control unit - removal and installation
• High pressure fuel pump (TNVD) - removal and installation
• High-pressure fuel pump components - removal and installation
• Fuel injectors - checking, removing and installing
• Fuel rail (Common rail system) - removal and installation
• Collectors - removal and installation
• Turbocharger - description
• Turbocharger - removal and installation
• Intercooler - removal and installation
• Exhaust system components - general information and component replacement

Emission control systems

• General information and precautions
• Emission control systems (gasoline engines) - checking and replacing components
• Emission control systems (diesel engines) - check and replace components
• Catalytic converter - general information and precautions