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
• 1.4 Engine data
  2
• 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
  8
• 1.6 Assembly mountings
  9
• Crankshaft group
  11
• 1 Dismantling and assembling engine
  11
• 1.1 Dismantling and assembling engine
  11
• 1.2 Removing and installing ribbed belt
  23
• 1.3 Checking semi-automatic toothed belt tensioning roller
  24
• 1.4 Removing single part injection pump sprocket
  25
• 2 Removing and installing sealing flange and flywheel
  27
• 2.1 Removing and installing sealing flange and flywheel
  27
• 2.2 Renewing crankshaft oil seal -pulley end
  31
• 3 Removing and installing crankshaft
  34
• 3.1 Removing and installing crankshaft
  34
• 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
  45
• 4.3 Piston and cylinder dimensions
  47
• Cylinder head, Valve gear
  48
• 1 Removing and installing cylinder head
  48
• 1.1 Removing and installing cylinder head
  48
• 1.2 Removing and installing intake pipes
  55
• 1.3 Removing, installing and tensioning toothed belt
  57
• 1.4 Removing and installing cylinder head
  67
• 1.5 Checking compression pressures
  70
• 2 Servicing valve gear
  74
• 2.1 Servicing valve gear
  74
• 2.2 Reworking valve seats
  80
• 2.3 Checking valve guides
  82
• 2.4 Renewing valve guides
  84
• 2.5 Renewing valve stem seals
  85
• 2.6 Removing and installing camshaft
  88
• 2.7 Checking hydraulic bucket tappets
  90
• 2.8 Replacing swirl chambers
  91
• Lubrication
  93
• 1 Removing and installing parts of the lubrication system
  93
• 1.1 Removing and installing parts of the lubrication system
  93
• 1.2 Checking oil pressure and oil pressure switch
  101
• Cooling system
  104
• 1 Removing and installing parts of cooling system
  104
• 1.1 Removing and installing parts of cooling system
  104
• 1.2 Parts of cooling system body side
  105
• 1.3 Parts of cooling system engine side
  108
• 1.4 Removing and installing coolant pump and compact bracket
  112
• 1.5 Draining and filling cooling system
  115
• 1.6 Removing and installing radiator
  117
• Fuel supply system
  119
• 1 Removing and installing parts of fuel supply system
  119
• 1.1 Removing and installing parts of fuel supply system
  119
• 1.2 Removing and installing fuel tank with its attachments
  120
• 1.3 Servicing fuel filter
  126
• 1.4 Safety precautions when working on the fuel supply system
  128
• 1.5 Rules for cleanliness
  129
• 1.6 Removing and installing fuel tank
  129
• 2 Accelerator mechanism: Engine code AEF
  131
• 2.1 Accelerator mechanism: Engine code AEF
  131
• 2.2 Servicing accelerator mechanism
  131
• 3 Accelerator mechanism: > 09.99 (Engine codes AGD, AHG, AKU)
  134
• 3.1 Accelerator mechanism: > 09.99 (Engine codes AGD, AHG, AKU)
  134
• 3.2 Servicing accelerator mechanism
  134
• 3.3 Checking accelerator pedal position sender adjustment
  136
• 3.4 Checking accelerator pedal position sender
  138
• 4 Accelerator mechanism: 10.99 > (Engine codes AGD, AKU, ASX)
  142
• 4.1 Accelerator mechanism: 10.99 > (Engine codes AGD, AKU, ASX)
  142
• 4.2 Servicing accelerator mechanism
  143
• 4.3 Checking accelerator pedal position sender
  143
• 4.4 Accelerator mechanism: 10.99 > (RHD vehicles)
  146
• 4.5 Servicing accelerator mechanism
  146
• 4.6 Checking accelerator pedal position sender
  147
• 4.7 Adjusting pedal position sender
  150
• Exhaust system
  151
• 1 Removing and installing parts of exhaust system
  151
• 1.1 Removing and installing parts of exhaust system
  151
• 1.2 Exhaust manifold, front exhaust pipe and catalyst with attachments
  151
• 1.3 Silencer with mountings
  153
• 2 Exhaust gas recirculation system: Engine code AEF
  155
• 2.1 Exhaust gas recirculation system: Engine code AEF
  155
• 2.2 Removing and installing parts of exhaust gas recirculation system
  156
• 2.3 Checking exhaust gas recirculation
  157
• 2.4 Checking exhaust gas recirculation valve (mechanical)
  159
• 2.5 Checking EGR valve (electrical)
  159
• 3 Exhaust gas recirculation system: Engine codes AGD, AHG, AKU, ASX
  160
• 3.1 Exhaust gas recirculation system: Engine codes AGD, AHG, AKU, ASX
  160
• 3.2 Removing and installing parts of exhaust gas recirculation system
  161
• 3.3 Connection diagram for vacuum hoses
  163
• 3.4 Checking exhaust gas recirculation valve (mechanical)
  164
• 3.5 Checking EGR valve
  165