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

Chapter overview

• Technical data
  1
• 1 Marking
  1
• 1.1 Engine number/engine data
  1
• 2 General information
  3
• 2.1 Numbering of cylinders
  3
• 3 Safety information
  4
• 3.1 Safety precautions when working on fuel system
  4
• 3.2 Safety measures when working on vehicles with a start/stop system
  5
• 3.4 Safety precautions when working on the cooling system
  6
• 4 Repair instructions
  7
• 4.1 Rules for cleanliness
  7
• 4.2 Foreign objects in engine
  8
• 4.3 Checking vacuum system
  8
• Removing and installing engine
  9
• 1 Removing and installing motor
  9
• 1.1 Removing motor
  9
• 1.2 Separating engine and gearbox
  21
• 1.3 Securing engine on engine and gearbox support
  26
• 1.4 Installing engine
  28
• 2 Assembly mountings
  32
• 2.1 Assembly overview - assembly mountings
  32
• 2.2 Removing and installing engine mounting
  34
• 2.3 Removing and installing gearbox mounting
  42
• 2.4 Removing and installing pendulum support
  43
• 2.5 Supporting engine in installation position
  44
• 2.6 Adjusting assembly mountings
  51
• 2.7 Checking adjustment of assembly mountings (engine and gearbox mountings)
  53
• 3 Engine cover panel
  55
• 3.1 Removing and installing engine cover
  55
• Crankshaft group
  56
• 1 Cylinder block (pulley end)
  56
• 1.1 Assembly overview - poly V-belt drive
  56
• 1.2 Assembly overview - sealing flange, belt pulley end
  60
• 1.3 Removing and installing poly-V belt
  62
• 1.4 Removing and installing tensioner for poly V-belt
  66
• 1.5 Removing and installing vibration damper
  68
• 1.6 Removing and installing bracket for ancillaries
  69
• 1.7 Removing and installing engine bracket
  71
• 1.8 Renewing crankshaft oil seal - belt pulley end
  74
• 1.9 Removing and installing sealing flange on pulley end
  77
• 2 Cylinder block, gearbox end
  82
• 2.1 Assembly overview - cylinder block, gearbox end
  82
• 2.2 Removing and installing flywheel
  83
• 2.3 Removing and installing sealing flange on gearbox side
  85
• 3 Crankshaft
  99
• 3.1 Assembly overview - crankshaft
  99
• 3.2 Crankshaft dimensions
  100
• 3.3 Renewing needle bearing in crankshaft
  100
• 3.4 Measuring axial clearance of crankshaft
  102
• 3.5 Measuring radial clearance of crankshaft
  103
• 4 Pistons and conrods
  105
• 4.1 Assembly overview - pistons and conrods
  105
• 4.2 Measuring piston projection at TDC
  107
• 4.3 Checking pistons and cylinder bores
  109
• 4.4 Separating new conrod
  112
• 4.5 Checking radial clearance of conrods
  113
• Cylinder head, valve gear
  114
• 1 Cylinder head
  114
• 1.1 Assembly overview - cylinder head
  114
• 1.2 Assembly overview - cylinder head cover
  118
• 1.3 Removing and installing cylinder head
  120
• 1.4 Removing and installing cylinder head cover
  135
• 1.5 Removing and installing injector seals
  138
• 1.6 Removing and installing vacuum pump
  139
• 1.7 Checking compression
  141
• 2 Toothed belt drive
  144
• 2.1 Assembly overview - toothed belt
  144
• 2.2 Removing and installing toothed belt
  147
• 3 Valve gear
  171
• 3.1 Assembly overview - valve gear
  171
• 3.2 Measuring axial play of camshaft
  173
• 3.3 Measuring radial play of camshaft
  174
• 3.4 Removing and installing camshaft oil seal
  175
• 3.5 Removing and installing camshaft
  183
• 3.6 Checking hydraulic compensation elements
  192
• 3.7 Removing and installing valve stem seals
  193
• 4 Inlet and exhaust valves
  202
• 4.1 Reworking valve seats
  202
• 4.2 Checking valve guides
  202
• 4.3 Checking valves
  203
• 4.4 Valve dimensions
  203
• Lubrication
  204
• 1 Sump, oil pump
  204
• 1.1 Assembly overview - sump/oil pump
  204
• 1.2 Engine oil:
  210
• 1.3 Removing and installing oil sump
  211
• 1.4 Removing and installing oil pump
  215
• 1.5 Removing and installing oil level and oil temperature sender G266
  218
• 2 Engine oil cooler
  220
• 2.1 Assembly overview - engine oil cooler
  220
• 2.2 Removing and installing engine oil cooler
  220
• 3 Oil filter, oil pressure switch
  224
• 3.1 Assembly overview - oil filter housing, oil pressure switch
  224
• 3.2 Removing and installing oil pressure switch F1
  225
• 3.3 Checking oil pressure
  226
• 3.4 Checking oil pressure and oil pressure switch
  227
• 3.5 Removing and installing oil filter housing
  228
• 4 Oil circuit
  233
• 4.1 Assembly overview - oil circuit
  233
• 4.2 Removing and installing oil return line for turbocharger
  233
• 5 Balancer shaft module
  239
• 5.1 Removing and installing balance shaft module
  239
• Cooling
  249
• 1 Cooling system/coolant
  249
• 1.1 Connection diagram - coolant hoses
  249
• 1.2 Checking cooling system for leaks
  251
• 1.3 Draining and adding coolant
  252
• 2 Coolant pump, regulation of cooling system
  261
• 2.1 Assembly overview - coolant pump, thermostat
  261
• 2.2 Assembly overview - electric coolant pump
  261
• 2.3 Removing and installing electric coolant pump
  262
• 2.4 Removing and installing coolant pump
  265
• 2.5 Removing and installing 4/2-way valve with thermostat
  267
• 2.6 Removing and installing coolant temperature sender G62
  273
• 2.7 Removing and installing radiator outlet coolant temperature sender G83
  275
• 3 Coolant pipes
  278
• 3.1 Assembly overview - coolant pipes
  278
• 3.2 Removing and installing coolant pipes
  280
• 4 Radiator, radiator fan
  293
• 4.1 Assembly overview - radiator/radiator fan
  293
• 4.2 Removing and installing radiator
  294
• 4.3 Removing and installing radiator cowl with radiator fan
  295
• 4.4 Removing and installing radiator fan
  297
• Turbocharging/supercharging
  298
• 1 Turbocharger
  298
• 1.1 Assembly overview - turbocharger
  298
• 1.2 Removing and installing turbocharger
  300
• 1.3 Renewing vacuum unit for turbocharger
  307
• 2 Charge air system
  315
• 2.1 Assembly overview - charge air system
  315
• 2.2 Assembly overview - charge-air hose connections
  317
• 2.3 Removing and installing charge air cooler
  319
• 2.4 Removing and installing charge pressure sender G31
  321
• 2.5 Checking charge air system for leaks
  322
• Mixture preparation - injection
  326
• 1 Injection system
  326
• 1.1 Schematic overview - fuel system
  326
• 1.2 Filling/bleeding fuel system
  328
• 1.3 Checking fuel system for leaks
  329
• 2 Vacuum system
  330
• 2.1 Assembly overview - vacuum system
  330
• 2.2 Checking vacuum system
  331
• 3 Injectors/high-pressure accumulator (rail)
  335
• 3.1 Assembly overview - injectors
  335
• 3.2 Assembly overview - fuel system
  336
• 3.3 Adapting correction values for injectors
  339
• 3.4 Testing jammed-open injectors
  340
• 3.5 Removing and installing injectors
  341
• 3.6 Removing and installing high-pressure lines
  345
• 3.7 Removing and installing fuel rail
  349
• 4 Air filter
  354
• 4.1 Assembly overview - air filter housing
  354
• 4.2 Removing and installing air filter housing
  356
• 5 Intake manifold
  359
• 5.1 Assembly overview - intake manifold
  359
• 5.2 Removing and installing intake manifold
  361
• 5.3 Removing and installing throttle valve module J338
  365
• 6 Senders and sensors
  367
• 6.1 Checking fuel pressure regulating valve N276
  367
• 6.2 Removing and installing fuel pressure regulating valve N276
  368
• 6.3 Removing and installing fuel pressure sender G247
  370
• 6.4 Removing and installing air mass meter G70
  373
• 6.5 Removing and installing pressure differential sender G505
  374
• 7 Engine (motor) control unit
  378
• 7.1 Removing and installing engine control unit J623
  378
• 7.2 Removing and installing engine (motor) control unit J623 with protective housing
  379
• 8 High-pressure pump
  382
• 8.1 Assembly overview - high-pressure pump
  382
• 8.2 Removing and installing high-pressure pump
  384
• 9 Lambda probe
  391
• 9.1 Removing and installing Lambda probe
  391
• Exhaust system
  393
• 1 Exhaust pipes and silencers
  393
• 1.1 Assembly overview - silencers
  393
• 1.2 Removing and installing rear silencer
  395
• 1.3 Aligning exhaust system free of stress
  397
• 1.4 Installation position of clamp
  398
• 2 Emission control
  400
• 2.1 Assembly overview - emission control
  400
• 2.2 Removing and installing particulate filter
  403
• 3 Exhaust gas temperature regulation
  412
• 3.1 Removing and installing parts of exhaust gas temperature regulation
  412
• 4 Exhaust gas recirculation
  419
• 4.1 Assembly overview - exhaust gas recirculation
  419
• 4.2 Removing and installing exhaust gas recirculation cooler
  421
• 4.3 Checking changeover for exhaust gas recirculation cooler
  424
• 4.4 Checking exhaust gas recirculation cooler for leaks
  425
• 4.5 Cleaning exhaust gas recirculation system
  430
• Glow plug system
  438
• 1 Glow plug system
  438
• 1.1 Removing and installing glow plug
  438
• 1.2 Removing and installing automatic glow period control unit J179
  440
• 1.3 Removing and installing Hall sender G40
  442
• 1.4 Removing and installing engine speed sender G28
  443