4-cylinder diesel engine (1.9 l engine)

Kapitelübersicht

• Technical data
  1
• 1 Technical data
  1
• 1.1 Engine number
  1
• 1.2 Engine data
  1
• Removing and installing engine
  2
• 1 Removing and installing engine
  2
• 1.1 Removing engine
  2
• 1.2 Securing engine to assembly stand
  7
• 1.3 Notes on installing
  7
• 1.4 Assembly mountings
  10
• Crankshaft group
  12
• 1 Dismantling and assembling engine
  12
• 1.1 Assembly overview - poly V-belt drive
  12
• 1.2 Removing and installing poly V-belt
  13
• 1.3 Assembly overview - toothed belt drive
  15
• 1.4 Assembly overview - crankcase
  19
• 2 Sealing flange, seals and flywheel
  20
• 2.1 Assembly overview - sealing flanges and flywheel
  20
• 2.2 Renewing crankshaft oil seal - pulley end
  21
• 2.3 Removing and installing sealing flange - pulley end
  23
• 2.4 Renewing crankshaft sealing flange - flywheel end
  25
• 3 Crankshaft
  33
• 3.1 Assembly overview - crankshaft
  33
• 3.2 Crankshaft dimensions
  38
• 4 Dismantling and assembling pistons and conrods
  39
• 4.1 Assembly overview - pistons and conrods
  39
• 4.2 Separating new conrod
  40
• 4.3 Checking piston projection at TDC
  41
• 4.4 Piston and cylinder dimensions
  42
• 4.5 Piston rings, cylinder bore and piston installation position
  42
• Cylinder head, valve gear
  45
• 1 Cylinder head
  45
• 1.1 Assembly overview - cylinder head
  46
• 1.2 Removing and installing cylinder head cover
  49
• 1.3 Removing, installing and tensioning toothed belts
  51
• 1.4 Removing and installing cylinder head
  66
• 1.5 Checking compression
  71
• 2 Valve gear
  73
• 2.1 Assembly overview - valve gear
  73
• 2.2 Checking valve guides
  75
• 2.3 Renewing valve stem seals
  77
• 2.4 Removing and installing camshaft
  79
• 2.5 Removing and installing camshaft oil seal
  83
• Lubrication
  85
• 1 Engine oil
  85
• 1.1 Oil capacities
  85
• 1.2 Checking engine oil level
  85
• 2 Parts of lubrication system
  86
• 2.1 Assembly overview - oil pump, sump
  86
• 2.2 Removing and installing sump
  87
• 3 Oil filter bracket, oil pressure, engine oil cooler and oil supply line
  91
• 3.1 Assembly overview - oil filter bracket and engine oil cooler
  91
• 3.2 Checking oil pressure and oil pressure switch
  92
• 3.3 Assembly overview - oil supply line to turbocharger
  93
• 3.4 Removing and installing oil supply line to turbocharger
  94
• Cooling
  97
• 1 Removing and installing parts of cooling system
  97
• 1.1 Assembly overview - parts of cooling system, body side (radiator with two radiator fans)
  98
• 1.3 Parts of cooling system, engine side
  100
• 1.4 Coolant hose schematic diagram
  102
• 1.5 Draining and filling with coolant
  103
• 1.6 Removing and installing radiator
  106
• 1.7 Removing and installing coolant pump
  107
• 1.8 Removing and installing thermostat
  109
• 1.9 Checking cooling system for leaks
  111
• 1.10 Checking oil cooler for leaks
  113
• Fuel supply system
  115
• 1 Parts of fuel supply system
  115
• 1.1 Safety precautions when working on fuel supply system
  115
• 1.2 Rules for cleanliness
  116
• 1.3 Fuel tank with attachments
  117
• 1.4 Assembly overview - fuel filter (AVQ, BKC, BRU)
  119
• 1.5 Assembly overview - fuel filter (BLS, BXE, BXF, BXJ)
  120
• 1.6 Removing and installing fuel cooler
  121
• 1.7 Emptying fuel tank
  122
• 1.8 Removing and installing fuel tank
  126
• 1.9 Removing and installing fuel delivery unit
  127
• 1.10 Removing and installing fuel gauge sender
  129
• 1.11 Checking fuel pump
  130
• 1.12 Checking voltage supply and current draw of fuel pump
  132
• 1.13 Assembly overview - accelerator mechanism
  134
• 1.14 Checking tandem pump
  136
• 1.15 Removing and installing tandem pump
  140
• Turbocharging/supercharging
  144
• 1 Charge air system with turbocharger
  144
• 1.1 Safety precautions
  144
• 1.2 Rules for cleanliness
  144
• 1.3 Hose connections
  145
• 1.4 Assembly overview - turbocharger
  146
• 1.5 Removing and installing turbocharger
  150
• 1.6 Assembly overview - parts of charge air cooling
  152
• 1.7 Vacuum hose schematic diagram
  155
• 1.8 Checking charge air system for leaks
  156
• Mixture preparation - injection
  159
• 1 Diesel direct injection system
  159
• 1.1 Safety precautions
  159
• 1.2 Rules for cleanliness
  160
• 1.3 Assembly overview - unit injector
  160
• 1.4 Removing and installing unit injector
  162
• 1.5 Adjusting non-contact gap of unit injectors
  164
• 1.6 Removing and installing O-rings for unit injector
  165
• 1.7 Assembly overview - intake manifold
  167
• 1.8 Assembly overview - air filter
  169
• 2 Engine control unit
  170
• 2.1 Reading and erasing engine control unit fault memory
  170
• 2.2 Adapting functions and components
  171
• 2.3 Removing and installing engine control unit
  171
• 2.4 Removing and installing anti-theft engine control unit
  172
• Exhaust system
  176
• 1 Exhaust system
  176
• 1.1 Assembly overview - front exhaust pipe with catalytic converter
  176
• 1.2 Assembly overview - front exhaust pipe with particulate filter
  177
• 1.3 Assembly overview - silencers with mountings
  179
• 1.4 Aligning exhaust system free of stress
  181
• 2 Exhaust gas recirculation system
  182
• 2.1 Assembly overview - parts of exhaust gas recirculation
  182
• Glow plug system
  185
• 1 Checking glow plug system
  185
• 1.1 Checking glow plug system
  185