4-Cyl. diesel engine, Mechanics

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
  3
• 1 Removing and installing engine
  3
• 1.1 Removing and installing engine
  3
• 1.2 Notes on removing
  3
• 1.3 Notes on installing
  5
• 1.4 Tightening torques
  7
• 1.5 Assembly mountings
  7
• 1.6 Renewing engine carrier rubber mounting
  8
• 1.7 Additional information and removal instructions for vehicles with air conditioner
  9
• Crankshaft group
  10
• 1 Dismantling and assembling engine
  10
• 1.1 Dismantling and assembling engine
  10
• 1.2 Removing and installing ribbed belt
  24
• 1.3 Removing and installing toothed belt
  27
• 1.4 Checking semi-automatic toothed belt tensioning roller
  33
• 1.5 Removing single part injection pump sprocket
  33
• 2 Removing and installing sealing flange and pressure plate/flywheel/drive plate
  34
• 2.1 Removing and installing sealing flange and pressure plate/flywheel/drive plate
  34
• 2.2 Renewing crankshaft oil seal - pulley end -
  38
• 2.3 Removing and installing drive plate
  39
• 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 Removing and installing cylinder head
  63
• 1.3 Checking compressions
  65
• 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
  80
• 2.8 Replacing swirl chambers
  81
• 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
  90
• 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
  95
• 1.4 Dismantling and assembling coolant pump
  98
• 1.5 Draining and filling cooling system
  99
• 1.6 Removing and installing radiator and radiator fan
  101
• Fuel supply system
  103
• 1 Removing and installing parts of fuel supply system
  103
• 1.1 Removing and installing parts of fuel supply system
  103
• 1.2 Removing and installing fuel tank with its attachments, front drive
  104
• 1.3 Fuel tank with its attachments, four wheel drive
  107
• 1.4 Safety precautions when working on the fuel supply system
  111
• 1.5 Rules for cleanliness
  112
• 1.6 Removing and installing fuel delivery unit, four wheel drive
  112
• 1.7 Servicing accelerator mechanism
  116
• 1.8 Servicing cold start accelerator (CSA) operating cable
  118
• 1.9 Adjusting CSA operating cable
  119
• Charging
  120
• 1 Charge air system with turbocharger
  120
• 1.1 Charge air system with turbocharger
  120
• 1.2 Removing and installing turbocharger with attachments
  120
• 1.3 Removing and installing parts of charge air cooling system
  131
• 1.4 Rules for cleanliness
  132
• 1.5 Turbocharger hose/pipe connections
  133
• 1.6 Removing and installing turbocharger
  135
• 1.7 Checking turbocharger
  139
• 1.8 Checking pressure unit for charge pressure regulating valve
  142
• 1.9 Removing and installing pressure unit for charge pressure regulating valve
  143
• Exhaust system
  144
• 1 Removing and installing parts of exhaust system, front wheel drive
  144
• 1.1 Removing and installing parts of exhaust system, front wheel drive
  144
• 1.2 Engine code 1Y
  145
• 1.4 Front exhaust pipe and catalyst with attachments, engine codes AFN, AVG
  148
• 1.6 Silencer with mountings, engine codes 1Z, AEY, AFN, AVG, AHU, ALE
  150
• 1.7 Engine code AAZ
  153
• 2 Removing and installing parts of exhaust system, four wheel drive
  155
• 2.1 Removing and installing parts of exhaust system, four wheel drive
  155
• 2.2 Front exhaust pipe and catalyst with attachments
  156
• 2.3 Silencer with mountings
  158
• 3 Exhaust gas recirculation system, engine codes 1Y, AEY
  160
• 3.1 Exhaust gas recirculation system, engine codes 1Y, AEY
  160
• 3.2 Removing and installing parts of exhaust gas recirculation system
  161
• 3.3 Checking exhaust gas recirculation
  162
• 3.4 Checking exhaust gas recirculation valve
  163
• 3.5 Checking two-way valve
  163
• 4 Exhaust gas recirculation system, engine codes AFN, AVG, AHU, ALE, 1Z
  164
• 4.1 Exhaust gas recirculation system, engine codes AFN, AVG, AHU, ALE, 1Z
  164
• 4.2 Removing and installing parts of exhaust gas recirculation system
  165
• 4.3 Vacuum hose connection diagram
  168
• 4.4 Checking exhaust gas recirculation valve (mechanical)
  170
• 5 Exhaust gas recirculation system, engine code AAZ
  171
• 5.1 Exhaust gas recirculation system, engine code AAZ
  171
• 5.2 Removing and installing parts of exhaust gas recirculation system
  172
• 5.3 Checking exhaust gas recirculation
  173
• 5.4 Checking exhaust gas recirculation valve
  174
• 5.5 Checking two-way valve
  174