4-cylinder diesel engine, mechanics

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Engine number
  1
• 1.2 Engine data
  1
• Removing and installing engine
  3
• 1 Removing and installing engine
  3
• 1.1 Removing engine
  4
• 1.2 Securing engine to assembly stand
  7
• 1.3 Notes on installing
  7
• 1.4 Torque settings
  8
• 1.5 Aligning engine and gearbox mountings
  8
• 1.6 Specified torques for 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 Overview
  13
• 1.2 Removing and installing idler roller
  16
• 1.3 Removing and installing poly V-belt
  16
• 1.4 Checking semi-automatic toothed belt tensioner
  17
• 2.1 Renewing crankshaft oil seal - belt pulley end
  20
• 2.2 Removing and installing drive plate
  22
• 2.3 Removing and installing front sealing flange
  24
• 3 Removing and installing crankshaft
  27
• 3.1 Crankshaft dimensions
  28
• 4 Dismantling and assembling pistons and conrods
  29
• 4.1 Checking piston projection at TDC
  31
• 4.2 Piston and cylinder dimensions
  32
• Cylinder head, valve gear
  33
• 1 Assembly overview - Cylinder head
  33
• 1.1 Assembly overview - Intake manifold
  35
• 1.2 Removing, installing and tensioning toothed belt
  36
• 1.3 Removing and installing cylinder head
  43
• 1.4 Checking compression
  46
• 2 Assembly overview - Valve gear
  48
• 2.1 Reworking valve seats
  50
• 2.2 Checking valve guides
  52
• 2.3 Renewing valve guides
  53
• 2.4 Renewing valve stem seals
  53
• 2.5 Removing and installing camshaft
  55
• 2.6 Checking hydraulic bucket tappets
  58
• Lubrication
  60
• 1 Parts of lubrication system
  60
• 1.1 Engine oil
  60
• 1.2 Removing and installing parts of lubrication system
  60
• 1.3 Removing and installing sump
  67
• 1.4 Checking oil pressure and oil pressure switch
  68
• Cooling
  71
• 1 Removing and installing parts of cooling system
  71
• 1.1 Parts of cooling system - body side
  71
• 1.2 Parts of cooling system - engine side
  73
• 1.3 Coolant hose schematic diagram
  74
• 1.4 Draining and filling coolant
  75
• 1.5 Removing and installing radiator
  78
• 1.6 Removing and installing coolant pump
  79
• 1.7 Removing and installing thermostat
  81
• Fuel supply system
  84
• 1 Removing and installing parts of fuel supply system
  84
• 1.1 Safety precautions when working on fuel supply system
  84
• 1.2 Rules for cleanliness
  84
• 1.3 Assembly overview - Fuel tank with attachments
  85
• 1.4 Assembly overview - fuel filter
  90
• 1.5 Removing and installing fuel tank
  90
• 1.6 Removing and installing fuel pump
  93
• 1.7 Checking fuel pump
  95
• 1.8 Removing and installing suction jet pump
  96
• 1.9 Assembly overview - Accelerator mechanism
  98
• 1.10 Checking accelerator pedal position sender
  100
• 1.11 Adjusting accelerator pedal position sender
  105
• Turbocharging/supercharging
  106
• 1 Charge air system with turbocharger
  106
• 1.1 Safety precautions
  106
• 1.2 Rules for cleanliness
  106
• 1.3 Turbocharger with attachments
  106
• 1.4 Assembly overview - Parts of charge air cooling
  111
• 1.5 Turbocharger wiring connections
  112
• 2 Checking charge pressure system
  114
• 2.1 Checking wastegate pressure unit
  114
• 2.2 Removing and installing wastegate pressure unit
  114
• 2.3 Checking charge pressure control
  115
• Exhaust system
  123
• 1 Removing and installing parts of exhaust system
  123
• 1.4 Silencer with attachments, engine codes AGR, AHF, ALH, ASV
  126
• 1.5 Silencer with mountings, engine codes AGP, AQM
  128
• 1.6 Silencer with mountings for vehicles with four-wheel drive
  129
• 2 Exhaust gas recirculation system
  131
• 2.1 Removing and installing parts of exhaust gas recirculation system
  131
• 2.2 Vacuum hose schematic diagram
  132
• 2.3 Checking exhaust gas recirculation valve
  134
• 2.4 Checking exhaust gas recirculation
  135