4-cyl. diesel engine with distributor injection pump

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
  8
• 1.4 Notes on installing
  8
• 1.5 Tightening torques
  9
• 1.6 Assembly mountings
  10
• 1.7 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
  19
• 1.3 Checking semi-automatic toothed belt tensioning roller
  21
• 2 Removing and installing sealing flange and flywheel
  22
• 2.1 Removing and installing sealing flange and flywheel
  22
• 2.2 Renewing crankshaft oil seal -pulley end
  26
• 2.3 Removing and installing sealing flange, pulley end
  29
• 3 Removing and installing crankshaft
  32
• 3.1 Removing and installing crankshaft
  32
• 3.2 Crankshaft dimensions
  35
• 4 Dismantling and assembling pistons and conrods
  36
• 4.1 Dismantling and assembling pistons and conrods
  36
• 4.2 Checking piston projection at TDC
  42
• 4.3 Piston and cylinder dimensions
  43
• Cylinder head, Valve gear
  44
• 1 Removing and installing cylinder head
  44
• 1.1 Removing and installing cylinder head
  44
• 1.2 Removing, installing and tensioning toothed belt
  48
• 1.3 Removing and installing cylinder head
  54
• 1.4 Checking compression pressures
  60
• 2 Servicing valve gear
  62
• 2.1 Servicing valve gear
  62
• 2.2 Reworking valve seats
  68
• 2.3 Checking valve guides
  70
• 2.4 Renewing valve stem seals
  71
• 2.5 Removing and installing camshaft
  73
• 2.6 Checking hydraulic bucket tappets
  76
• Lubrication
  78
• 1 Removing and installing parts of the lubrication system
  78
• 1.1 Removing and installing parts of the lubrication system
  78
• 1.2 Removing and installing sump
  86
• 1.3 Checking oil pressure and oil pressure switch
  89
• Cooling system
  92
• 1 Removing and installing parts of cooling system
  92
• 1.1 Removing and installing parts of cooling system
  92
• 1.2 Parts of cooling system body side
  93
• 1.3 Parts of cooling system engine side
  97
• 1.4 Coolant hose connection diagram
  100
• 1.5 Draining and filling cooling system
  102
• 1.6 Removing and installing coolant pump
  105
• 1.7 Removing and installing radiator
  107
• 1.8 Removing and installing thermostat
  109
• Fuel supply system
  111
• 1 Removing and installing parts of fuel supply system
  111
• 1.1 Removing and installing parts of fuel supply system
  111
• 1.2 Removing and installing fuel tank with its attachments
  112
• 1.3 Servicing fuel filter
  117
• 1.4 Safety precautions when working on the fuel supply system
  120
• 1.5 Rules for cleanliness
  120
• 1.6 Removing and installing fuel tank
  121
• 1.7 Removing and installing fuel delivery unit
  123
• 1.8 Removing and installing fuel gauge sender
  125
• 1.9 Servicing accelerator mechanism
  126
• Mixture preparation, Injection
  127
• 1 Servicing Diesel direct injection system
  127
• 1.1 Servicing Diesel direct injection system
  127
• 1.2 Safety precautions
  127
• 1.3 Rules for cleanliness
  127
• 1.4 Servicing injection pump
  128
• 1.5 Dismantling and assembling intake manifold
  133
• 1.6 Removing and installing injection pump
  135
• 1.7 Removing and installing injectors
  140
• 1.8 Checking injectors
  141
• 1.9 Renewing injection timing device cover O-ring
  142
• 2 Engine control unit
  143
• 2.1 Engine control unit
  143
• 2.2 Removing and installing engine control unit
  143
• 2.3 Interrogating and erasing engine control unit fault memory
  143
• 2.4 Adapting functions and components
  144
• Exhaust system
  146
• 1 Removing and installing parts of exhaust system
  146
• 1.1 Removing and installing parts of exhaust system
  146
• 1.2 Dismantling and assembling exhaust system
  146
• 2 Exhaust gas recirculation system
  150
• 2.1 Exhaust gas recirculation system
  150
• 2.2 Removing and installing parts of exhaust gas recirculation system
  151
• 2.3 Connection diagram for vacuum hoses
  152
• 2.4 Checking exhaust gas recirculation valve (mechanical)
  153
• Glow plug system
  154
• 1 Checking glow plug system
  154
• 1.1 Checking glow plug system
  154
• 1.2 Checking glow plugs
  155