4-cylinder diesel engine (1.6 l engine, common rail)

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety precautions when working on the cooling system
  1
• 1.2 Safety measures when working on fuel supply
  2
• 1.4 Safety precautions when working on injection system
  3
• 2 Identification
  4
• 2.1 Engine number/engine data
  4
• 3 General information
  5
• 3.1 General notes on injection
  5
• 3.2 General notes on the lubrication system
  5
• 3.3 General notes on fuel system
  6
• 4 Repair instructions
  8
• 4.1 Rules for cleanliness when working on fuel supply system
  8
• 4.2 Rules for cleanliness when working on injection system
  8
• 4.3 Rules for cleanliness when working on turbocharger
  9
• 4.4 Foreign objects in engine
  9
• Removing and installing engine
  10
• 1 Removing and installing engine
  10
• 1.1 Removing engine
  10
• 1.2 Separating engine from gearbox
  22
• 1.3 Separating engine from dual clutch gearbox
  23
• 1.4 Securing engine on engine and gearbox support
  25
• 1.5 Installing engine
  26
• 2 Assembly mountings
  32
• 2.1 Assembly overview - assembly mountings
  32
• 2.2 Removing and installing engine mounting
  35
• 2.3 Removing and installing engine bracket
  37
• 2.4 Supporting engine in installation position
  40
• 2.5 Adjusting assembly mountings
  43
• 3 Engine cover panel
  47
• 3.1 Removing and installing engine cover
  47
• Crankshaft group
  48
• 1 Cylinder block (pulley end)
  48
• 1.1 Assembly overview - cylinder block
  48
• 1.2 Assembly overview - sealing flange, belt pulley end
  50
• 1.3 Assembly overview - poly V-belt drive without air conditioner compressor
  51
• 1.4 Assembly overview - poly V-belt drive with air conditioning compressor
  52
• 1.5 Assembly overview - ancillary bracket
  53
• 1.6 Removing and installing sealing flange on pulley end
  53
• 1.7 Renewing crankshaft oil seal - belt pulley end
  56
• 1.8 Removing and installing bracket for ancillaries
  58
• 1.9 Removing and installing poly V-belt without air conditioner compressor
  61
• 1.10 Removing and installing poly V-belt with air conditioner compressor
  61
• 1.11 Removing and installing tensioner for poly V-belt
  63
• 1.12 Removing and installing vibration damper
  64
• 2 Cylinder block, gearbox end
  66
• 2.1 Assembly overview - flywheel
  66
• 2.2 Removing and installing flywheel
  67
• 2.3 Removing and installing sealing flange on gearbox side
  68
• 3 Crankshaft
  76
• 3.1 Assembly overview - crankshaft
  76
• 3.2 Crankshaft dimensions
  77
• 3.3 Renewing needle bearing in crankshaft
  77
• 4 Pistons and conrods
  79
• 4.1 Assembly overview - pistons and conrods
  79
• 4.2 Checking pistons and cylinder bores
  81
• 4.3 Piston and cylinder dimensions
  82
• 4.4 Separating new conrod
  82
• 4.5 Measuring piston projection at TDC
  83
• 4.6 Checking radial clearance of conrods
  84
• 4.7 Removing and installing oil spray jets
  85
• Cylinder head, valve gear
  87
• 1 Cylinder head
  87
• 1.1 Assembly overview - cylinder head
  87
• 1.2 Assembly overview - cylinder head cover
  89
• 1.3 Removing and installing cylinder head
  91
• 1.4 Removing and installing cylinder head cover
  106
• 1.5 Removing and installing injector seals
  111
• 1.6 Removing and installing vacuum pump
  114
• 1.7 Checking compression
  115
• 2 Fully enclosing toothed belt guard
  117
• 2.1 Assembly overview - fully enclosing toothed belt guard
  117
• 2.2 Removing and installing upper toothed belt guard (fully enclosing)
  118
• 2.3 Removing and installing lower toothed belt guard (fully enclosed)
  119
• 2.4 Removing and installing rear toothed belt guard (fully enclosing)
  120
• 3 Toothed belt drive
  125
• 3.1 Assembly overview - toothed belt drive
  125
• 3.2 Removing and installing toothed belt
  127
• 4 Valve gear
  141
• 4.1 Assembly overview - valve gear
  141
• 4.2 Removing and installing camshafts
  144
• 4.3 Measuring axial play of camshaft
  151
• 4.4 Measuring radial play of camshaft
  152
• 4.5 Removing and installing camshaft oil seal
  152
• 4.6 Checking hydraulic compensation elements
  155
• 4.7 Removing and installing valve stem seals
  155
• 4.8 Removing and installing valve stem seals with cylinder head removed
  159
• 5 Inlet and exhaust valves
  163
• 5.1 Reworking valve seats
  163
• 5.2 Checking valve guides
  163
• 5.3 Checking valves
  164
• 5.4 Valve dimensions
  164
• Lubrication
  165
• 1 Sump, oil pump
  165
• 1.1 Assembly overview - sump/oil pump
  165
• 1.2 Removing and installing sump
  167
• 1.3 Removing and installing oil pump
  171
• 1.4 Engine oil:
  173
• 1.5 Removing and installing oil level and oil temperature sender G266
  173
• 1.6 Measuring oil consumption
  174
• 2 Engine oil cooler
  175
• 2.1 Removing and installing engine oil cooler
  175
• 3 Oil filter, oil pressure switch
  179
• 3.1 Assembly overview - oil filter housing with engine oil cooler
  179
• 3.2 Removing and installing oil filter housing
  180
• 3.3 Removing and installing oil pressure switch F1
  183
• 3.4 Checking oil pressure switch
  185
• 3.5 Checking oil pressure
  186
• 4 Oil circuit
  188
• 4.1 Assembly overview - oil circuit
  188
• 4.2 Removing and installing oil supply line
  189
• Cooling
  193
• 1 Cooling system/coolant
  193
• 1.1 Connection diagram - coolant hoses
  193
• 1.2 Draining and adding coolant
  194
• 1.3 Checking cooling system for leaks
  202
• 1.4 Checking engine oil cooler for leaks
  204
• 2 Coolant pump, regulation of cooling system
  206
• 2.1 Assembly overview - coolant pump, thermostat
  206
• 2.2 Assembly overview - coolant pump and thermostat, from week 22/2011
  207
• 2.3 Removing and installing coolant pump
  207
• 2.4 Removing and installing 4/2-way valve with thermostat
  208
• 2.5 Removing and installing coolant temperature sender G62
  214
• 2.6 Removing and installing radiator outlet coolant temperature sender G83
  215
• 2.7 Removing and installing coolant circulation pump 2 V178
  216
• 3 Radiator, radiator fan
  219
• 3.1 Assembly overview - radiator/radiator fan
  219
• 3.3 Removing and installing radiator
  221
• 4 Coolant pipes
  224
• 4.1 Assembly overview - coolant pipes
  224
• 4.2 Removing and installing lower coolant pipe
  225
• 4.3 Removing and installing upper coolant pipe
  229
• 4.4 Removing and installing left coolant pipe
  230
• 4.5 Removing and installing right coolant pipe
  232
• Turbocharging/supercharging
  235
• 1 Turbocharger
  235
• 1.1 Assembly overview - turbocharger
  235
• 1.2 Removing and installing turbocharger
  239
• 1.3 Removing and installing charge pressure control solenoid valve N75
  244
• 2 Charge air system
  247
• 2.1 Assembly overview - charge air system
  247
• 2.2 Assembly overview - charge-air hose connections
  248
• 2.3 Removing and installing charge air cooler
  249
• 2.4 Removing and installing charge air pipe
  251
• 2.5 Removing and installing charge air pressure sender G31 / intake air temperature sender G42
  252
• 2.6 Checking charge air system for leaks
  252
• Mixture preparation - injection
  256
• 1 Injection system
  256
• 1.1 Schematic overview - fuel system
  256
• 1.2 Overview of fitting locations - injection system
  258
• 1.3 Assembly overview - fuel system
  267
• 1.4 Checking fuel system for leaks
  270
• 1.5 Filling/bleeding fuel system
  270
• 2 Vacuum system
  272
• 2.1 Connection diagram - vacuum system
  272
• 2.2 Checking vacuum system
  273
• 3 Injectors/high-pressure accumulator (rail)
  281
• 3.1 Overview - fuel return lines
  281
• 3.2 Assembly overview - injectors
  282
• 3.3 Removing and installing high-pressure lines
  282
• 3.4 Removing and installing fuel rail
  288
• 3.5 Removing and installing injectors
  292
• 3.6 Adapting correction values for injectors
  297
• 3.7 Replacing O-ring of fuel return lines
  298
• 3.8 Check pressure retention valve in fuel return line
  298
• 3.9 Checking return flow rate of injectors at starter speed
  300
• 3.10 Testing injectors
  301
• 4 High-pressure pump
  303
• 4.1 Assembly overview - high-pressure pump
  303
• 4.2 Removing and installing high-pressure pump
  304
• 4.3 Pressure testing high-pressure pump
  308
• 4.4 Checking high-pressure pump
  310
• 5 Intake manifold
  313
• 5.1 Assembly overview - intake manifold
  313
• 5.2 Removing and installing intake manifold
  314
• 5.3 Removing and installing throttle valve module GX3
  318
• 6 Air filter
  320
• 6.1 Assembly overview - air filter housing
  320
• 6.2 Removing and installing air filter housing
  321
• 7 Lambda probe
  323
• 7.1 Removing and installing Lambda probe G39
  323
• 8 Senders and sensors
  325
• 8.1 Removing and installing air mass meter G70
  325
• 8.2 Removing and installing pressure differential sender G505
  326
• 8.3 Removing and installing fuel pressure regulating valve N276
  326
• 8.4 Checking fuel pressure regulating valve N276
  329
• 8.5 Removing and installing fuel pressure sender G247
  331
• 8.6 Checking fuel pressure sender G 247
  334
• 8.7 Checking fuel metering valve N 290
  335
• 9 Engine control unit
  336
• 9.1 Removing and installing engine control unit J623
  336
• 9.2 Removing and installing anti-theft engine control unit J623
  337
• Exhaust system
  340
• 1 Exhaust pipes and silencers
  340
• 1.1 Assembly overview - silencers
  340
• 1.2 Separating exhaust pipes from silencers
  341
• 1.3 Aligning exhaust system free of stress
  342
• 1.4 Installation position of clamp
  343
• 2 Emission control
  344
• 2.1 Assembly overview - catalytic converter
  344
• 2.2 Assembly overview - particulate filter
  346
• 2.3 Removing and installing particulate filter
  347
• 3 Exhaust gas temperature regulation
  352
• 3.1 Assembly overview - exhaust gas temperature regulation
  352
• 3.2 Removing and installing exhaust gas temperature sender 1 G235
  353
• 3.3 Removing and installing exhaust gas temperature sender 3 G495
  354
• 3.4 Removing and installing exhaust gas temperature sender 4 G648
  356
• 4 Exhaust gas recirculation
  359
• 4.1 Assembly overview - exhaust gas recirculation
  359
• 4.2 Checking changeover for exhaust gas recirculation cooler
  360
• 4.3 Removing and installing exhaust gas recirculation cooler
  361
• 4.4 Checking exhaust gas recirculation cooler for leaks
  363
• 4.5 Cleaning exhaust gas recirculation system
  364
• Glow plug system
  371
• 1 Glow plug system
  371
• 1.1 Removing and installing glow plug
  371
• 1.2 Checking glow plugs
  373
• 1.3 Removing and installing automatic glow period control unit J179
  373
• 1.4 Removing and installing engine speed sender G28
  374
• 1.5 Removing and installing Hall sender G40
  375