4-cyl. diesel engine with unit injector

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
  4
• 1.3 Securing engine to assembly stand
  6
• 1.4 Notes on installing
  6
• 1.5 Tightening torques
  7
• 1.6 Assembly mountings
  7
• 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
  22
• 2 Removing and installing sealing flange and flywheel
  25
• 2.1 Removing and installing sealing flange and flywheel
  25
• 2.2 Renewing crankshaft oil seal -pulley end
  28
• 2.3 Removing and installing sealing flange, pulley end
  31
• 3 Removing and installing crankshaft
  34
• 3.1 Removing and installing crankshaft
  34
• 3.2 Crankshaft dimensions
  38
• 4 Dismantling and assembling pistons and conrods
  39
• 4.1 Dismantling and assembling pistons and conrods
  39
• 4.2 Checking piston projection at TDC
  45
• 4.3 Piston and cylinder dimensions
  46
• Cylinder head, Valve gear
  47
• 1 Removing and installing cylinder head
  47
• 1.1 Removing and installing cylinder head
  47
• 1.2 Removing and installing cylinder head cover
  55
• 1.3 Removing, installing and tensioning toothed belt
  57
• 1.4 Removing and installing cylinder head
  64
• 1.5 Checking compression pressures
  67
• 2 Servicing valve gear
  69
• 2.1 Servicing valve gear
  69
• 2.2 Checking valve guides
  76
• 2.3 Renewing valve stem seals
  78
• 2.4 Removing and installing camshaft
  80
• 2.5 Removing and installing camshaft oil seal
  84
• Lubrication
  86
• 1 Removing and installing parts of the lubrication system
  86
• 1.1 Removing and installing parts of the lubrication system
  86
• 1.2 Removing and installing sump
  98
• 1.3 Checking oil pressure and oil pressure switch
  100
• Cooling system
  102
• 1 Removing and installing parts of cooling system
  102
• 1.1 Removing and installing parts of cooling system
  102
• 1.2 Parts of cooling system body side
  103
• 1.3 Parts of cooling system engine side
  106
• 1.4 Coolant hose connection diagram
  110
• 1.5 Draining and filling cooling system
  112
• 1.6 Removing and installing radiator
  115
• 1.7 Removing and installing coolant pump
  116
• 1.8 Removing and installing thermostat
  118
• Fuel supply system
  120
• 1 Removing and installing parts of fuel supply system
  120
• 1.1 Removing and installing parts of fuel supply system
  120
• 1.2 Removing and installing fuel tank with its attachments
  121
• 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 cooler
  129
• 1.7 Removing and installing fuel tank
  130
• 1.8 Removing and installing fuel delivery unit
  132
• 1.9 Removing and installing fuel gauge sender
  134
• 1.10 Checking fuel pump
  135
• 1.11 Servicing accelerator mechanism
  137
• 1.12 Checking tandem pump
  138
• 1.13 Removing and installing tandem pump
  140
• Charging
  143
• 1 Charge air system with turbocharger
  143
• 1.1 Charge air system with turbocharger
  143
• 1.2 Safety precautions
  143
• 1.3 Rules for cleanliness
  143
• 1.4 Removing and installing turbocharger with attachments
  143
• 1.5 Removing and installing parts of charge air cooling
  152
• Mixture preparation, Injection
  156
• 1 Servicing Diesel direct injection system
  156
• 1.1 Servicing Diesel direct injection system
  156
• 1.2 Safety precautions
  156
• 1.3 Rules for cleanliness
  156
• 1.4 Servicing intake manifold flap
  157
• 1.5 Servicing unit injector
  160
• 1.6 Removing and installing O rings for unit injector
  162
• 1.7 Removing and installing unit injector
  164
• 2 Engine control unit
  168
• 2.1 Engine control unit
  168
• 2.2 Interrogating and erasing engine control unit fault memory
  168
• 2.3 Adapting functions and components
  169
• 2.4 Removing and installing engine control unit
  169
• Exhaust system
  171
• 1 Removing and installing parts of exhaust system
  171
• 1.1 Removing and installing parts of exhaust system
  171
• 1.2 Aligning exhaust system ensuring connections are stress-free
  173
• 2 Exhaust gas recirculation system
  174
• 2.1 Exhaust gas recirculation system
  174
• 2.2 Removing and installing parts of exhaust gas recirculation system
  175
• Ignition system
  177
• 1 Checking glow plug system
  177
• 1.1 Checking glow plug system
  177
• 1.2 Checking glow plugs
  178