4-Cyl. diesel engine with unit injector, 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
  4
• 1.3 Securing engine to assembly stand
  7
• 1.4 Notes on installing
  7
• 1.5 Tightening torques
  9
• 1.6 Assembly mountings
  9
• 1.7 Additional information and removal instructions for vehicles with air conditioner
  10
• Crankshaft group
  12
• 1 Dismantling and assembling engine
  12
• 1.1 Dismantling and assembling engine
  12
• 1.2 Removing and installing ribbed belt
  27
• 2 Removing and installing sealing flange and flywheel
  29
• 2.1 Removing and installing sealing flange and flywheel
  29
• 2.2 Removing and installing drive plate
  32
• 2.3 Renewing crankshaft oil seal -pulley end
  35
• 2.4 Removing and installing sealing flange, pulley end
  38
• 3 Removing and installing crankshaft
  41
• 3.1 Removing and installing crankshaft
  41
• 3.2 Crankshaft dimensions
  44
• 4 Dismantling and assembling pistons and conrods
  45
• 4.1 Dismantling and assembling pistons and conrods
  45
• 4.2 Checking piston projection at TDC
  51
• 4.3 Piston and cylinder dimensions
  52
• Cylinder head, Valve gear
  53
• 1 Removing and installing cylinder head
  53
• 1.1 Removing and installing cylinder head
  53
• 1.2 Removing, installing and tensioning toothed belt
  60
• 1.3 Removing and installing cylinder head
  72
• 1.4 Checking compression pressures
  77
• 2 Servicing valve gear
  79
• 2.1 Servicing valve gear
  79
• 2.2 Reworking valve seats
  86
• 2.3 Checking valve guides
  88
• 2.4 Renewing valve stem seals
  89
• 2.5 Removing and installing camshaft
  91
• 2.6 Removing and installing camshaft oil seal
  95
• Lubrication
  97
• 1 Removing and installing parts of the lubrication system
  97
• 1.1 Removing and installing parts of the lubrication system
  97
• 1.2 Removing and installing sump
  104
• 1.3 Checking oil pressure and oil pressure switch
  107
• Cooling system
  110
• 1 Removing and installing parts of cooling system
  110
• 1.1 Removing and installing parts of cooling system
  110
• 1.2 Parts of cooling system body side
  111
• 1.3 Parts of cooling system engine side
  115
• 1.4 Coolant hose connection diagram
  120
• 1.5 Draining and filling cooling system
  123
• 1.6 Removing and installing radiator
  125
• 1.7 Removing and installing coolant pump
  127
• 1.8 Removing and installing thermostat
  129
• Fuel supply system
  131
• 1 Removing and installing parts of fuel supply system
  131
• 1.1 Removing and installing parts of fuel supply system
  131
• 1.2 Removing and installing fuel tank with its attachments
  131
• 1.3 Servicing fuel filter
  136
• 1.4 Safety precautions when working on the fuel supply system
  138
• 1.5 Rules for cleanliness
  139
• 1.6 Removing and installing fuel cooler
  139
• 1.7 Servicing accelerator mechanism
  140
• 1.8 Checking accelerator pedal position sender
  141
• 1.9 Checking tandem pump
  143
• 1.10 Removing and installing tandem pump
  146
• Charging
  149
• 1 Charge air system with turbocharger
  149
• 1.1 Charge air system with turbocharger
  149
• 1.2 Removing and installing turbocharger with attachments
  149
• 1.3 Removing and installing parts of charge air cooling
  156
• 1.4 Hose connection diagram for charge pressure control
  159
• 1.5 Rules for cleanliness
  162
• 2 Checking charge pressure system
  163
• 2.1 Checking charge pressure system
  163
• 2.2 Checking pressure unit for charge pressure regulating valve
  163
• 2.3 Removing and installing pressure unit for charge pressure regulating valve
  164
• 2.4 Checking turbocharger
  165
• 2.5 Checking charge pressure control
  167
• Exhaust system
  174
• 1 Removing and installing parts of exhaust system
  174
• 1.1 Removing and installing parts of exhaust system
  174
• 1.2 Exhaust manifold, front exhaust pipe and catalyst with attachments
  174
• 1.3 Silencer with mountings
  176
• 2 Exhaust gas recirculation system
  177
• 2.1 Exhaust gas recirculation system
  177
• 2.2 Removing and installing parts of exhaust gas recirculation system
  178
• 2.3 Checking exhaust gas recirculation valve (mechanical)
  184
• 2.4 Checking exhaust gas recirculation
  185