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

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety regulations for working on fuel supply
  1
• 1.2 Safety measures when working on vehicles with start/stop system
  1
• 1.4 Safety precautions when working on the cooling system
  2
• 1.5 Safety precautions when working on ignition system
  2
• 1.6 Safety precautions when working on exhaust system
  3
• 2 Identification
  4
• 2.1 Engine number/engine data
  4
• 3 Repair instructions
  6
• 3.1 Rules for cleanliness
  6
• 3.2 General information
  7
• 3.3 Foreign objects in engine
  7
• 3.4 Contact corrosion
  8
• 3.5 Routing and attachment of lines
  8
• 3.6 Fitting radiator and condensers
  8
• 3.7 Checking vacuum system
  8
• Removing and installing engine
  10
• 1 Removing and installing engine
  10
• 1.1 Removing engine
  10
• 1.2 Separating engine and gearbox
  22
• 1.3 Securing engine on engine and gearbox support
  26
• 1.4 Installing engine
  28
• 2 Assembly mountings
  33
• 2.1 Assembly overview - assembly mountings
  33
• 2.2 Removing and installing engine mounting
  35
• 2.3 Removing and installing gearbox mounting
  38
• 2.4 Removing and installing pendulum support
  39
• 2.5 Supporting engine in installation position
  42
• 2.6 Adjusting assembly mountings
  44
• 2.7 Checking adjustment of assembly mountings
  48
• 3 Engine cover panel
  50
• 3.1 Removing and installing engine cover
  50
• Crankshaft group
  51
• 1 Cylinder block (pulley end)
  51
• 1.1 Assembly overview - poly V-belt drive
  51
• 1.2 Assembly overview - cylinder block (pulley end)
  53
• 1.3 Assembly overview - sealing flange, belt pulley end
  56
• 1.4 Removing and installing poly-V belt
  57
• 1.5 Removing and installing tensioner for poly V-belt
  59
• 1.6 Removing and installing vibration damper
  60
• 1.7 Removing and installing bracket for ancillaries
  61
• 1.8 Removing and installing engine support
  64
• 1.9 Renewing crankshaft oil seal - belt pulley end
  66
• 1.10 Removing and installing sealing flange on pulley end
  68
• 2 Cylinder block, gearbox end
  73
• 2.1 Assembly overview - cylinder block, gearbox end
  73
• 2.2 Removing and installing flywheel
  74
• 2.3 Removing and installing sealing flange on gearbox side
  75
• 3 Crankshaft
  86
• 3.1 Assembly overview - crankshaft
  86
• 3.2 Crankshaft dimensions
  87
• 3.3 Renewing needle bearing in crankshaft
  88
• 3.4 Measuring axial clearance of crankshaft
  90
• 4 Pistons and conrods
  92
• 4.1 Assembly overview - pistons and conrods
  92
• 4.2 Removing and installing pistons
  95
• 4.3 Measuring piston projection at TDC
  96
• 4.4 Checking pistons and cylinder bores
  98
• 4.5 Separating new conrod
  100
• 4.6 Checking radial clearance of conrods
  101
• 4.7 Removing and installing oil spray jets
  101
• Cylinder head, valve gear
  103
• 1 Cylinder head
  103
• 1.1 Assembly overview - cylinder head
  103
• 1.2 Assembly overview - cylinder head cover
  107
• 1.3 Removing and installing cylinder head
  109
• 1.4 Removing and installing cylinder head cover
  125
• 1.5 Removing and installing injector seals
  132
• 1.6 Removing and installing vacuum pump
  133
• 1.7 Checking compression
  135
• 2 Fully enclosing toothed belt guard
  137
• 2.1 Assembly overview - fully enclosing toothed belt guard
  137
• 2.2 Removing and installing upper toothed belt guard (fully enclosing)
  139
• 2.3 Removing and installing lower toothed belt guard (fully enclosed)
  140
• 2.4 Removing and installing rear toothed belt guard (fully enclosing)
  141
• 3 Toothed belt drive
  146
• 3.1 Assembly overview - toothed belt
  146
• 3.2 Removing and installing toothed belt
  149
• 4 Valve gear
  165
• 4.1 Assembly overview - valve gear
  165
• 4.2 Measuring axial play of camshaft
  168
• 4.3 Measuring radial play of camshaft
  169
• 4.4 Removing and installing camshaft oil seal
  169
• 4.5 Removing and installing camshaft
  172
• 4.6 Checking hydraulic compensation elements
  181
• 4.7 Removing and installing valve stem seals
  182
• 5 Inlet and exhaust valves
  192
• 5.1 Reworking valve seats
  192
• 5.2 Checking valve guides
  192
• 5.3 Checking valves
  193
• 5.4 Valve dimensions
  193
• Lubrication
  194
• 1 Sump, oil pump
  194
• 1.1 Assembly overview - sump/oil pump
  194
• 1.2 Engine oil:
  197
• 1.3 Removing and installing oil sump
  198
• 1.4 Removing and installing oil pump
  202
• 1.5 Removing and installing oil level and oil temperature sender G266
  204
• 2 Engine oil cooler
  206
• 2.1 Assembly overview - engine oil cooler
  206
• 2.2 Removing and installing engine oil cooler
  206
• 3 Oil filter, oil pressure switch
  211
• 3.1 Assembly overview - oil filter housing, oil pressure switch
  211
• 3.2 Removing and installing oil filter housing
  212
• 3.3 Removing and installing oil pressure switch F1
  215
• 3.4 Checking oil pressure and oil pressure switch
  217
• 4 Oil circuit
  219
• 4.1 Assembly overview - oil circuit
  219
• 4.2 Removing and installing oil return line for turbocharger
  220
• Cooling
  226
• 1 Cooling system/coolant
  226
• 1.1 Connection diagram - coolant hoses
  226
• 1.2 Checking cooling system for leaks
  228
• 1.3 Draining and adding coolant
  233
• 2 Coolant pump, regulation of cooling system
  243
• 2.1 Assembly overview - coolant pump, thermostat
  243
• 2.2 Removing and installing coolant circulation pump 2 V178
  243
• 2.3 Removing and installing coolant pump
  246
• 2.4 Removing and installing 4/2-way valve with thermostat
  247
• 2.5 Removing and installing coolant temperature sender G62
  249
• 2.6 Removing and installing radiator outlet coolant temperature sender G83
  251
• 3 Coolant pipes
  254
• 3.1 Assembly overview - coolant pipes
  254
• 3.2 Removing and installing coolant pipes
  256
• 4 Radiator, radiator fan
  264
• 4.1 Assembly overview - radiator, radiator fan
  264
• 4.2 Assembly overview – radiator cowl and radiator fan
  265
• 4.3 Removing and installing radiator
  266
• 4.4 Removing and installing radiator cowl with radiator fan
  267
• 4.5 Removing and installing radiator fan VX57
  268
• 4.6 Removing and installing radiator fan 2 V177
  269
• Turbocharging/supercharging
  271
• 1 Turbocharger
  271
• 1.1 Assembly overview - turbocharger
  271
• 1.2 Removing and installing turbocharger
  274
• 2 Charge air system
  279
• 2.1 Assembly overview - charge air system
  279
• 2.2 Assembly overview - charge-air hose connections
  281
• 2.3 Removing and installing charge air cooler
  282
• 2.5 Checking charge air system for leaks
  285
• 2.6 Removing and installing air pipe
  289
• Mixture preparation - injection
  292
• 1 Injection system
  292
• 1.1 Schematic overview - fuel system
  292
• 1.2 Overview of fitting locations - injection system
  294
• 1.3 Assembly overview - fuel system
  297
• 1.4 Filling/bleeding fuel system
  300
• 1.5 Checking fuel system for leaks
  301
• 2 Vacuum system
  302
• 2.1 Connection diagram – vacuum system
  302
• 2.2 Checking vacuum system
  303
• 3 Injectors/high-pressure accumulator (rail)
  315
• 3.1 Assembly overview - injectors
  315
• 3.2 Assembly overview - fuel rail
  316
• 3.3 Adapting correction values for injectors
  316
• 3.4 Testing injectors
  317
• 3.5 Checking return flow rate of injectors with engine running
  318
• 3.6 Checking return flow rate of injectors at starter speed
  321
• 3.7 Testing jammed-open injectors
  323
• 3.8 Check pressure retention valve in fuel return line
  324
• 3.9 Removing and installing injectors
  326
• 3.10 Removing and installing high-pressure lines
  332
• 3.11 Removing and installing fuel rail
  336
• 4 Air filter
  340
• 4.1 Assembly overview - air filter housing
  340
• 4.2 Removing and installing air filter housing
  342
• 5 Intake manifold
  345
• 5.1 Assembly overview – intake manifold
  345
• 5.2 Removing and installing intake manifold
  347
• 5.3 Removing and installing throttle valve module GX3
  351
• 6 Senders and sensors
  352
• 6.1 Removing and installing fuel pressure regulating valve N276
  352
• 6.2 Checking fuel pressure regulating valve N276
  354
• 6.3 Removing and installing fuel pressure sender G247
  356
• 6.4 Removing and installing air mass meter G70
  358
• 6.5 Removing and installing pressure differential sender G505
  359
• 7 Engine control unit
  360
• 7.1 Removing and installing engine (motor) control unit J623 with protective housing
  360
• 8 High-pressure pump
  363
• 8.1 Assembly overview - high-pressure pump
  363
• 8.2 Removing and installing high-pressure pump
  363
• 8.3 Checking high-pressure pump
  367
• 9 Lambda probe
  370
• 9.1 Removing and installing Lambda probe
  370
• Exhaust system
  372
• 1 Exhaust pipes and silencers
  372
• 1.1 Assembly overview – silencers
  372
• 1.2 Separating exhaust pipes from silencers
  373
• 1.3 Aligning exhaust system free of stress
  374
• 1.4 Checking exhaust system for leaks
  376
• 1.5 Installation position of clamp
  376
• 2 Emission control
  379
• 2.1 Assembly overview – emission control
  379
• 2.2 Removing and installing particulate filter
  381
• 3 Exhaust gas temperature regulation
  388
• 3.1 Assembly overview – exhaust gas temperature regulation
  388
• 3.2 Removing and installing exhaust gas temperature sender 1 G235
  389
• 3.3 Removing and installing exhaust gas temperature sender 3 G495
  391
• 3.4 Removing and installing exhaust gas temperature sender 4 G648
  393
• 4 Exhaust gas recirculation
  395
• 4.1 Assembly overview – exhaust gas recirculation
  395
• 4.2 Removing and installing exhaust gas recirculation cooler
  397
• 4.3 Checking exhaust gas recirculation cooler for leaks
  399
• 4.4 Checking changeover for exhaust gas recirculation cooler
  399
• 4.5 Cleaning exhaust gas recirculation system
  400
• Glow plug system
  410
• 1 Glow plug system
  410
• 1.1 Removing and installing glow plug
  410
• 1.2 Checking glow plug
  412
• 1.3 Removing and installing automatic glow period control unit J179
  412
• 1.4 Removing and installing Hall sender G40
  413
• 1.5 Removing and installing engine speed sender G28
  414