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
  2
• 1 Removing and installing engine
  2
• 1.1 Removing and installing engine
  2
• 1.2 Notes on removing
  3
• 1.3 Securing engine to assembly stand
  5
• 1.4 Notes on installing
  6
• 1.5 Tightening torques
  8
• 1.6 Assembly mountings
  8
• Crankshaft group
  10
• 1 Dismantling and assembling engine
  10
• 1.1 Dismantling and assembling engine
  10
• 1.2 Removing and installing ribbed belt
  20
• 1.3 Removing, installing and tensioning toothed belt
  21
• 1.4 Checking semi-automatic toothed belt tensioning roller
  26
• 1.5 Removing single part injection pump sprocket
  27
• 2 Removing and installing sealing flange and flywheel
  28
• 2.1 Removing and installing sealing flange and flywheel
  28
• 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
  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
  53
• 1.3 Checking compression pressures
  55
• 2 Servicing valve gear
  57
• 2.1 Servicing valve gear
  57
• 2.2 Reworking valve seats
  63
• 2.3 Checking valve guides
  64
• 2.4 Renewing valve guides
  65
• 2.5 Renewing valve stem seals
  66
• 2.6 Removing and installing camshaft
  69
• 2.7 Checking hydraulic bucket tappets
  71
• Lubrication
  73
• 1 Removing and installing parts of the lubrication system
  73
• 1.1 Removing and installing parts of the lubrication system
  73
• 1.2 Checking oil pressure and oil pressure switch
  80
• Cooling system
  82
• 1 Removing and installing parts of cooling system
  82
• 1.1 Removing and installing parts of cooling system
  82
• 1.2 Parts of cooling system body side
  83
• 1.3 Parts of cooling system engine side
  86
• 1.4 Coolant hose connection diagram
  89
• 1.5 Removing and installing coolant pump and compact bracket
  90
• 1.6 Draining and filling cooling system
  92
• 1.7 Removing and installing radiator
  94
• Fuel supply system
  96
• 1 Removing and installing parts of fuel supply system
  96
• 1.1 Removing and installing parts of fuel supply system
  96
• 1.2 Removing and installing fuel tank with its attachments
  96
• 1.3 Servicing fuel filter
  101
• 1.4 Safety precautions when working on the fuel supply system
  103
• 1.5 Rules for cleanliness
  104
• 1.6 Removing and installing fuel tank
  104
• 1.7 Servicing accelerator mechanism (80-pin control unit)
  106
• 1.8 Checking accelerator pedal position sender (80-pin control unit)
  108
• 1.9 Adjusting pedal position sender (80-pin control unit)
  111
• 1.10 Servicing accelerator mechanism (121-pin control unit)
  113
• 1.11 Checking accelerator pedal position sender (121-pin control unit)
  116
• 1.12 Adjusting pedal position sender (121-pin control unit)
  120
• Exhaust system
  122
• 1 Removing and installing parts of exhaust system
  122
• 1.1 Removing and installing parts of exhaust system
  122
• 2 Exhaust gas recirculation system
  125
• 2.1 Exhaust gas recirculation system
  125
• 2.2 Removing and installing parts of exhaust gas recirculation system
  126
• 2.3 Vacuum hose connection diagram
  127
• 2.4 Checking exhaust gas recirculation valve (mechanical)
  128
• 2.5 Checking exhaust gas recirculation valve
  129