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

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 and installing engine cover panel
  3
• 1.2 Removing engine
  4
• 1.3 Separating engine from gearbox
  12
• 1.4 Securing engine on engine and gearbox support
  14
• 1.5 Installing engine
  16
• 1.6 Notes on installing
  18
• 1.7 Assembly mountings
  20
• 1.8 Setting up support bracket
  21
• Crankshaft group
  24
• 1 Removing and installing poly V-belt
  24
• 1.1 Assembly overview - poly V-belt drive without air conditioning compressor
  24
• 1.2 Assembly overview \- poly V-belt drive with tensioning element and air conditioner compressor
  25
• 1.3 Removing and installing poly V-belt without air conditioner compressor
  25
• 1.4 Removing and installing poly V-belt with tensioning element
  26
• 1.5 Removing and installing tensioning element for poly V-belt
  27
• 2 Dismantling and assembling engine
  31
• 2.1 Assembly overview - ancillary bracket
  31
• 2.2 Removing and installing ancillary bracket
  31
• 2.3 Removing and installing vibration damper
  33
• 2.4 Assembly overview - toothed belt drive
  34
• 2.5 Removing and installing engine bracket
  36
• 2.6 Assembly overview - crankcase
  41
• 3 Removing and installing sealing flange and flywheel
  43
• 3.1 Assembly overview - sealing flanges and flywheel
  43
• 3.2 Removing and installing dual-mass flywheel
  44
• 3.3 Renewing crankshaft sealing flange - flywheel end
  46
• 3.4 Renewing crankshaft oil seal - pulley end
  54
• 3.5 Removing and installing sealing flange - pulley end
  55
• 4 Removing and installing engine speed sender G28
  58
• 5 Pistons and conrods
  60
• 5.1 Assembly overview - pistons and conrods
  60
• 5.2 Measuring piston projection at „TDC“
  64
• 5.3 Piston and cylinder dimensions
  65
• 5.4 Measuring radial clearance of conrods
  65
• 6 Crankshaft
  67
• 6.1 Assembly overview - crankshaft
  67
• Cylinder head, valve gear
  69
• 1 Cylinder head
  69
• 1.1 Assembly overview - cylinder head
  69
• 1.2 Removing and installing Hall sender G40
  71
• 1.3 Assembly overview - cylinder head cover
  74
• 1.4 Removing and installing cylinder head cover
  75
• 1.5 Removing and installing injector seal in cylinder head cover
  79
• 1.6 Removing, installing and tensioning toothed belts
  82
• 1.7 Removing and installing cylinder head
  96
• 1.8 Removing and installing vacuum pump
  110
• 1.9 Checking compression
  110
• 2 Valve gear
  113
• 2.1 Assembly overview - valve gear
  113
• 2.2 Measuring axial clearance of camshaft
  114
• 2.3 Measuring radial clearance of camshafts
  115
• 2.4 Valves
  116
• 2.5 Renewing valve stem seals with cylinder head removed
  119
• 2.6 Removing and installing camshafts
  122
• 2.7 Checking hydraulic compensation elements
  129
• 2.8 Removing and installing camshaft oil seal
  130
• Lubrication
  132
• 1 Engine oil
  132
• 1.1 Oil capacities
  132
• 1.2 Checking engine oil level
  132
• 2 Parts of lubrication system
  133
• 2.1 Assembly overview - oil pump, sump
  133
• 2.2 Removing and installing oil sump
  136
• 2.3 Removing and installing oil pump
  140
• 3 Oil filter bracket, oil pressure, engine oil cooler and oil supply line
  141
• 3.1 Assembly overview - oil filter bracket and engine oil cooler
  141
• 3.2 Removing and installing oil filter bracket with engine oil cooler
  143
• 3.3 Removing and installing engine oil cooler
  146
• 3.4 Checking engine oil cooler for leaks
  149
• 3.5 Checking oil pressure and oil pressure switch
  151
• 3.6 Removing and installing oil pressure switch F1
  154
• 4 Oil supply line and turbocharger support
  155
• 4.1 Assembly overview - oil supply line and turbocharger support
  155
• 4.2 Removing and installing oil supply line and turbocharger support
  156
• Cooling
  160
• 1 Cooling system
  160
• 1.1 Assembly overview - parts of cooling system, body side
  161
• 1.2 Assembly overview - cowling with radiator fan V7
  163
• 1.3 Parts of cooling system, engine side
  164
• 1.4 Assembly overview - coolant pump and 4/2-way valve with thermostat
  165
• 1.5 Removing and installing 4/2-way valve with thermostat
  165
• 1.6 Coolant hose schematic diagram
  170
• 1.7 Removing and installing cowling with radiator fan V7
  171
• 1.8 Removing and installing radiator and detaching charge air cooler from radiator
  172
• 1.9 Removing and installing coolant temperature sender G62
  176
• 1.11 Removing and installing coolant circulation pump 2 V178
  178
• 1.12 Removing and installing coolant pump
  179
• 1.13 Removing and installing front coolant pipe
  181
• 1.14 Removing and installing right coolant pipes
  184
• 2 Draining and replenishing coolant
  186
• 2.1 Draining and filling coolant
  186
• 2.2 Checking cooling system for leaks
  190
• Fuel supply system
  193
• 1 Safety precautions when working on fuel supply system
  193
• 2 Rules for cleanliness
  194
• 3 Repair instructions if tank has been filled with incorrect fuel
  195
• 3.1 Step 1 (Engine was started with incorrect fuel)
  195
• 3.2 Step 2 (Engine was not started with incorrect fuel)
  196
• 3.3 Step 3 (There are metal particles in fuel delivery unit and fuel tank)
  197
• 3.4 Step 4 (There are no metal particles in fuel delivery unit and fuel tank)
  198
• 3.5 Step 5 (There are metal particles in high-pressure pump)
  198
• 3.6 Step 6 (There are no metal particles in high-pressure pump)
  198
• 4 Emptying fuel tank
  199
• 4.1 Emptying fuel tank when fuel pump is intact
  199
• 4.2 Emptying fuel tank if it is more than 3/4 full
  202
• 4.3 Emptying fuel tank if it is less than 3/4 full
  203
• 5 Parts of fuel supply system
  205
• 5.1 Fuel tank
  205
• 5.2 Removing and installing fuel delivery unit
  210
• 6 Fuel gauge sender G 6
  213
• 7 Repairing fuel supply
  215
• 7.1 Assembly overview - fuel filter
  215
• 7.2 Removing and installing fuel filter
  217
• 7.3 Assembly overview - accelerator mechanism
  217
• 8 Testing low-pressure fuel systems (fuel pump)
  219
• 8.1 Distinguishing features of the various low-pressure fuel systems
  219
• 8.2 Checking fuel pump , vehicles with 0.5 bar low-pressure fuel system
  222
• 8.3 Checking fuel pump , vehicles with 6.0 bar low-pressure fuel system
  225
• Turbocharging/supercharging
  237
• 1 Charge air system with turbocharger
  237
• 1.1 Safety precautions
  237
• 1.2 Rules for cleanliness
  237
• 1.3 Assembly overview - turbocharger with attachments
  238
• 1.4 Removing and installing turbocharger
  241
• 1.5 Assembly overview - parts of charge air cooling
  245
• 1.6 Removing and installing charge air cooler
  247
• 1.7 Removing and installing charge air pipe »hot« side
  247
• 2 Checking charge air system
  249
• 2.1 Checking charge air system for leaks
  249
• 3 Vacuum system
  251
• 3.1 Vacuum hose schematic diagram
  251
• 3.2 Testing vacuum system
  252
• Mixture preparation - injection
  253
• 1 Safety precautions, rules for cleanliness, assembly instructions
  253
• 1.1 Safety precautions
  253
• 1.2 Rules for cleanliness
  253
• 1.3 Instructions for working on fuel system
  254
• 2 Mixture preparation, 1.6 l common rail
  256
• 2.1 System layouts
  256
• 2.2 Assembly overview - fuel system
  260
• 2.3 Assembly overview - installation position of clamp
  266
• 3 Removing and installing components of the diesel direct injection system
  267
• 3.1 Removing and installing injectors
  267
• 3.2 Removing and installing high-pressure lines
  272
• 3.3 Removing and installing high-pressure pump
  278
• 3.4 Removing and installing high-pressure accumulator
  282
• 3.5 Removing and installing fuel pressure regulating valve N276
  286
• 3.6 Removing and installing fuel pressure sender G247
  288
• 4 Filling/bleeding/checking the diesel direct injection system
  291
• 4.1 Filling/bleeding, checking high-pressure pump/fuel system
  291
• 4.2 Checks on high-pressure accumulator
  295
• 4.3 Checks on injector
  297
• 4.4 Checking fuel system for leaks
  300
• 4.5 Check pressure retention valve in fuel return line
  301
• 5 Intake manifold
  303
• 5.3 Removing and installing intake manifold (vehicles with intake manifold flap V157 )
  305
• 5.5 Removing and installing throttle valve module J338
  312
• 6 Air filter
  313
• 6.1 Assembly overview - air filter
  313
• 7 Engine control unit
  316
• 7.1 Removing and installing engine control unit with no ant-theft protection
  316
• 7.2 Removing and installing anti-theft engine control unit
  316
• Exhaust system
  318
• 1 Exhaust system
  318
• 1.1 Assembly overview - front exhaust pipe with catalytic converter
  318
• 1.2 Removing and installing catalytic converter
  319
• 1.3 Assembly overview - silencer
  324
• 1.4 Aligning exhaust system free of stress
  326
• 2 Exhaust gas recirculation system
  328
• 2.1 Assembly overview - parts of exhaust gas recirculation system
  328
• 2.2 Checking changeover for exhaust gas recirculation cooler
  329
• 2.3 Removing and installing exhaust gas recirculation system
  330
• Glow plug system
  334
• 1 Removing, installing and checking glow plugs
  334