4-Cyl. diesel engine, Mech.

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 Notes on installing
  4
• 1.4 Tightening torques
  5
• 1.5 Assembly mountings
  6
• 1.6 Aligning engine and gearbox
  8
• 1.7 Renewing engine carrier rubber mounting
  10
• 1.8 Additional information and removal instructions for vehicles with air conditioner
  11
• Crankshaft group
  12
• 1 Dismantling and assembling engine
  12
• 1.1 Dismantling and assembling engine
  12
• 1.2 Removing and installing ribbed belt
  26
• 1.3 Removing and installing toothed belt
  29
• 1.4 Checking semi-automatic toothed belt tensioning roller
  34
• 1.5 Removing single part injection pump sprocket
  34
• 2 Removing and installing sealing flanges and flywheel/drive plate
  36
• 2.1 Removing and installing sealing flanges and flywheel/drive plate
  36
• 2.2 Renewing crankshaft oil seal - pulley end -
  39
• 2.3 Removing and installing drive plate
  40
• 3 Removing and installing crankshaft
  43
• 3.1 Removing and installing crankshaft
  43
• 3.2 Crankshaft dimensions
  46
• 4 Dismantling and assembling pistons and conrods
  47
• 4.1 Dismantling and assembling pistons and conrods
  47
• 4.2 Checking piston projection at TDC
  54
• 4.3 Piston and cylinder dimensions
  55
• Cylinder head, Valve gear
  56
• 1 Removing and installing cylinder head
  56
• 1.1 Removing and installing cylinder head
  56
• 1.2 Installing cylinder head
  63
• 1.3 Checking compressions
  64
• 2 Servicing valve gear
  67
• 2.1 Servicing valve gear
  67
• 2.2 Reworking valve seats
  73
• 2.3 Checking valve guides
  75
• 2.4 Renewing valve guides
  76
• 2.5 Renewing valve stem seals
  76
• 2.6 Removing and installing camshaft
  78
• 2.7 Checking hydraulic bucket tappets
  79
• 2.8 Replacing swirl chambers
  80
• Lubrication
  82
• 1 Removing and installing parts of the lubrication system
  82
• 1.1 Removing and installing parts of the lubrication system
  82
• 1.2 Checking oil pressure and oil pressure switch
  89
• 1.3 Removing and installing oil sump cap
  89
• Cooling system
  91
• 1 Removing and installing parts of cooling system
  91
• 1.1 Removing and installing parts of cooling system
  91
• 1.2 Parts of cooling system body side
  92
• 1.3 Parts of cooling system - engine side
  96
• 1.4 Dismantling and assembling coolant pump
  99
• 1.5 Draining and filling cooling system
  100
• 1.6 Removing and installing radiator and radiator fan
  102
• Fuel supply system
  104
• 1 Removing and installing parts of fuel supply system
  104
• 1.1 Removing and installing parts of fuel supply system
  104
• 1.2 Removing and installing fuel tank with its attachments
  105
• 1.3 Safety precautions when working on the fuel supply system
  108
• 1.4 Rules for cleanliness
  108
• 1.5 Servicing accelerator mechanism
  109
• 1.6 Servicing cold start accelerator (CSA) operating cable
  111
• 1.7 Adjusting CSA operating cable
  112
• Charging
  113
• 1 Charge air system with turbocharger
  113
• 1.1 Charge air system with turbocharger
  113
• 1.2 Removing and installing turbocharger with attachments
  113
• 1.3 Removing and installing parts of charge air cooling system
  124
• 1.4 Rules for cleanliness
  127
• 1.5 Turbocharger hose/pipe connections
  128
• 1.6 Removing and installing turbocharger
  130
• 1.7 Checking turbocharger
  134
• 1.8 Checking pressure unit for charge pressure regulating valve
  137
• 1.9 Removing and installing pressure unit for charge pressure regulating valve
  138
• Exhaust system
  139
• 1 Removing and installing parts of exhaust system
  139
• 1.1 Removing and installing parts of exhaust system
  139
• 2 Exhaust gas recirculation system, engine codes 1Z and AHU
  149
• 2.1 Exhaust gas recirculation system, engine codes 1Z and AHU
  149
• 2.2 Removing and installing parts of exhaust gas recirculation system
  150
• 2.3 Checking exhaust gas recirculation valve (mechanical)
  151
• 2.4 Vacuum hose connection diagram
  153
• 3 Exhaust gas recirculation system, engine code AFN
  153
• 3.1 Exhaust gas recirculation system, engine code AFN
  153
• 3.2 Removing and installing parts of exhaust gas recirculation system
  154
• 3.3 Vacuum hose connection diagram
  155
• 3.4 Checking exhaust gas recirculation valve
  156
• 4 Exhaust gas recirculation system, engine code AAZ
  158
• 4.1 Exhaust gas recirculation system, engine code AAZ
  158
• 4.2 Removing and installing parts of exhaust gas recirculation system
  158
• 4.3 Exhaust gas recirculation system
  159
• 4.4 Checking exhaust gas recirculation
  160
• 4.5 Checking exhaust gas recirculation valve
  162
• 4.6 Checking two-way valve
  162
• 4.7 Checking engine temperature sender
  163
• 4.8 Checking and adjusting partial throttle switch
  164