4-cylinder diesel engine

Chapter overview

• Technical data
  1
• 1 Engine number/engine data
  1
• 1.1 Engine number/engine data
  1
• 2 Safety information
  2
• 2.1 Safety precautions when working on cooling system
  2
• 2.2 Safety measures when working on fuel supply
  3
• 2.3 Safety precautions when working on injection system
  4
• 3 Repair notes
  5
• 3.1 Rules for cleanliness when working on fuel supply system/injection system
  5
• 3.2 Rules for cleanliness during work on fuel system
  5
• Removing and installing engine
  6
• 1 Removing and installing engine
  6
• 1.1 Removing engine
  6
• 1.2 Securing engine to assembly stand
  12
• 1.3 Installing engine
  12
• 2 Assembly mountings
  15
• 2.1 Assembly overview - assembly mountings
  15
• Crankshaft group
  16
• 1 Cylinder block (pulley end)
  16
• 1.1 Assembly overview - poly V-belt drive
  16
• 1.2 Assembly overview - crankcase
  17
• 1.3 Removing and installing poly-V belt
  18
• 1.4 Renewing crankshaft oil seal - belt pulley end
  20
• 1.5 Removing and installing sealing flange on pulley end
  22
• 2 Cylinder block, gearbox end
  26
• 2.1 Assembly overview - cylinder block, gearbox end
  26
• 2.2 Removing and installing sealing flange on gearbox side
  28
• 3 Crankshaft
  37
• 3.1 Assembly overview - crankshaft
  37
• 3.2 Removing and installing sender wheel
  38
• 3.3 Crankshaft dimensions
  39
• 4 Pistons and conrods
  40
• 4.1 Assembly overview - pistons and conrods
  40
• 4.2 Measuring piston projection at TDC
  42
• 4.3 Checking pistons and cylinder bores
  43
• 4.4 Piston and cylinder dimensions
  44
• Cylinder head, valve gear
  45
• 1 Cylinder head
  45
• 1.1 Assembly overview - cylinder head
  45
• 1.2 Removing and installing cylinder head
  48
• 1.3 Removing and installing cylinder head cover
  56
• 1.4 Checking compression
  58
• 2 Toothed belt drive
  61
• 2.1 Assembly overview - toothed belt drive
  61
• 2.2 Removing and installing toothed belt, vehicles ► 12.05
  62
• 2.3 Removing and installing toothed belt, vehicles 01.06 ►
  70
• 3 Valve gear
  79
• 3.1 Assembly overview - valve gear
  79
• 3.2 Measuring axial clearance of camshaft
  80
• 3.3 Removing and installing camshaft oil seal
  81
• 3.4 Removing and installing camshaft
  83
• 3.5 Removing and installing valve stem seal
  88
• 4 Inlet and exhaust valves
  91
• 4.1 Checking valve guides
  91
• Lubrication
  92
• 1 Sump, oil pump
  92
• 1.1 Assembly overview - sump/oil pump
  92
• 1.2 Removing and installing sump
  93
• 1.3 Engine oil:
  96
• 2 Oil filter, oil pressure switch
  97
• 2.1 Assembly overview - oil filter housing, oil pressure switch
  97
• 2.2 Checking oil pressure and oil pressure switch
  98
• 2.3 Measuring oil consumption
  99
• 3 Oil circuit
  100
• 3.1 Assembly overview - oil supply line
  100
• 3.2 Removing and installing oil supply line
  100
• Cooling
  103
• 1 Cooling system/coolant
  103
• 1.1 Coolant hose schematic diagram - engine codes AXB and AXC
  103
• 1.2 Coolant hose schematic diagram - engine codes BRR and BRS
  104
• 1.3 Draining and adding coolant
  105
• 1.4 Checking cooling system for leaks
  112
• 2 Coolant pump, regulation of cooling system
  114
• 2.1 Assembly overview - coolant pump, thermostat
  114
• 2.2 Removing and installing coolant pump
  115
• 2.3 Removing and installing thermostat
  116
• 3 Radiator, radiator fan
  119
• 3.1 Assembly overview - radiator/radiator fan
  119
• 3.2 Removing and installing radiator
  120
• Turbocharging/supercharging
  123
• 1 Turbocharger
  123
• 1.1 Assembly overview - turbocharger, engine codes AXB and AXC
  123
• 1.2 Assembly overview - turbocharger, engine codes BRR and BRS
  125
• 1.3 Removing and installing turbocharger
  127
• 2 Charge air system
  129
• 2.1 Assembly overview - charge air system
  129
• 2.2 Assembly overview - charge-air hose connections
  130
• 2.3 Checking charge air system for leaks
  131
• Mixture preparation - injection
  133
• 1 Injectors
  133
• 1.1 Assembly overview - injectors
  133
• 1.2 Removing and installing O-rings for unit injector
  134
• 1.3 Removing and installing injectors
  135
• 1.4 Removing and installing prewiring for unit injectors
  138
• 2 Vacuum system
  142
• 2.1 Vacuum system schematic diagram - engine codes AXB and AXC
  142
• 2.2 Vacuum system schematic diagram - engine codes BRR and BRS, ► 2007
  143
• 2.3 Vacuum system schematic diagram - engine codes BRR and BRS, 2008 ►
  144
• 3 Air filter
  145
• 3.1 Assembly overview - air filter
  145
• 4 Intake manifold
  146
• 4.1 Assembly overview - intake manifold, engine codes BRR and BRS
  146
• 4.2 Assembly overview - intake manifold, engine codes AXB and AXC
  146
• 5 Engine control unit
  148
• 5.1 Removing and installing engine (motor) control unit J623
  148
• Exhaust system
  150
• 1 Exhaust pipes and silencers
  150
• 1.1 Assembly overview - silencers/catalytic converters
  150
• 1.2 Assembly overview - silencers/particulate filter
  151
• 1.3 Separating exhaust pipes from silencers
  152
• 2 Emission control
  153
• 2.1 Assembly overview - emission control
  153
• 2.2 Removing and installing particulate filter
  154
• 3 Exhaust gas recirculation
  158
• 3.1 Assembly overview - exhaust gas recirculation, engine codes AXB and AXC
  158
• 3.2 Assembly overview - exhaust gas recirculation, engine codes BRR and BRS
  159
• Glow plug system
  160
• 1 Glow plug system
  160
• 1.1 Removing and installing glow plugs Q10 / Q13
  160
• 1.2 Checking glow plugs Q10 / Q13
  162
• 1.3 Removing and installing engine speed sender G28
  164
• 1.4 Removing and installing Hall sender G40
  165