4-Cyl. Diesel engine, Mechanics (1.9 ltr. engine)

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Technical data
  1
• 1.2 Engine number
  1
• 1.3 Engine data
  1
• Removing and installing engine
  2
• 1 Removing and installing engine
  2
• 1.1 Removing and installing engine
  2
• 1.2 Notes on removing
  2
• 1.3 Securing engine to assembly stand
  4
• 1.4 Notes on installing
  5
• 1.5 Tightening torques
  6
• Crankshaft group
  7
• 1 Dismantling and assembling engine
  7
• 1.1 Dismantling and assembling engine
  7
• 1.2 Removing single part injection pump sprocket
  19
• 1.3 Adjusting alternator V-belt tension
  19
• 1.4 Removing and installing ribbed belt
  20
• 1.5 Removing and installing toothed belt
  22
• 1.6 Checking semi-automatic toothed belt tensioning roller
  28
• 2 Removing and installing sealing flange and flywheel
  30
• 2.1 Removing and installing sealing flange and flywheel
  30
• 2.2 Renewing crankshaft oil seal - pulley end -
  32
• 3 Removing and installing crankshaft
  35
• 3.1 Removing and installing crankshaft
  35
• 3.2 Crankshaft dimensions
  37
• 4 Dismantling and assembling pistons and conrods
  38
• 4.1 Dismantling and assembling pistons and conrods
  38
• 4.2 Checking piston projection at TDC
  43
• 4.3 Piston and cylinder dimensions
  44
• Cylinder head, Valve gear
  45
• 1 Removing and installing cylinder head
  45
• 1.1 Removing and installing cylinder head
  45
• 1.2 Removing and installing cylinder head
  51
• 1.3 Checking compressions
  52
• 2 Servicing valve gear
  54
• 2.1 Servicing valve gear
  54
• 2.2 Reworking valve seats
  59
• 2.3 Checking valve guides
  60
• 2.4 Renewing valve guides
  61
• 2.5 Renewing valve stem seals
  61
• 2.6 Removing and installing camshaft
  64
• 2.7 Checking hydraulic bucket tappets
  65
• 2.8 Replacing swirl chambers
  66
• Lubrication
  67
• 1 Removing and installing parts of the lubrication system
  67
• 1.1 Removing and installing parts of the lubrication system
  67
• 1.2 Checking oil pressure and oil pressure switch
  74
• Cooling system
  76
• 1 Removing and installing parts of cooling system
  76
• 1.1 Removing and installing parts of cooling system
  76
• 1.2 Parts of cooling system body side
  77
• 1.3 Parts of cooling system - engine side
  81
• 1.4 Coolant hose connection diagram
  85
• 1.5 Draining and filling cooling system
  86
• 1.6 Removing and installing radiator and radiator fan
  88
• 1.7 Checking thermo-switch and coolant circulation pump
  89
• Fuel supply system
  91
• 1 Removing and installing parts of fuel supply system
  91
• 1.1 Removing and installing parts of fuel supply system
  91
• 1.2 Removing and installing fuel tank with its attachments
  92
• 1.3 Safety precautions when working on the fuel supply system
  94
• 1.4 Rules for cleanliness
  95
• 1.5 Removing and installing fuel tank
  95
• 1.6 Removing and installing fuel gauge sender
  96
• 1.7 Servicing accelerator mechanism
  97
• 1.8 Adjusting accelerator cable
  98
• 1.9 Servicing cold start accelerator (CSA) operating cable
  99
• 1.10 Adjusting CSA operating cable
  101
• Charging
  102
• 1 Charge air system with turbocharger
  102
• 1.1 Charge air system with turbocharger
  102
• 1.2 Removing and installing exhaust turbocharger with attachments
  103
• 1.3 Rules for cleanliness
  105
• 1.4 Removing and installing turbocharger
  106
• 1.5 Checking turbocharger
  108
• Exhaust system
  109
• 1 Removing and installing parts of exhaust system
  109
• 1.1 Removing and installing parts of exhaust system
  109
• 1.2 Removing and installing clamping springs
  113
• 1.3 Tensioning and relieving tension on clamping springs
  114
• 2 Exhaust gas recirculation system, engine code ABL
  115
• 2.1 Exhaust gas recirculation system, engine code ABL
  115
• 2.2 Removing and installing parts of exhaust gas recirculation system
  115
• 2.3 Exhaust gas recirculation system
  116
• 2.4 Checking exhaust gas recirculation
  118
• 2.5 Checking exhaust gas recirculation valve
  120
• 2.6 Checking two-way valve
  120
• 2.7 Checking engine temperature sender (G27)
  121
• 2.8 Checking and adjusting partial throttle switch
  121