4-cylinder diesel engine (1.9 l engine)

Chapter overview

• Technical data
  1
• 1 Identification
  1
• 1.1 Engine number, engine data
  1
• 2 Safety instructions
  2
• 2.1 Safety precautions when working on cooling system
  2
• 2.2 Safety precautions when working on fuel supply system
  3
• 2.3 Safety precautions when working on charge air system
  4
• 2.4 Safety precautions when working on injection system
  4
• 3 Repair instructions
  6
• 3.1 Rules for cleanliness when working on fuel supply system/injection system
  6
• 3.2 Rules for cleanliness when working on charge air system
  6
• 3.3 General notes on the lubrication system
  7
• Removing and installing engine
  8
• 1 Removing and installing engine
  8
• 1.1 Removing engine
  8
• 1.2 Removing engine - vehicles with four-wheel drive
  14
• 1.3 Securing engine on engine and gearbox support VAS 6095
  21
• 1.4 Installing engine
  22
• 1.5 Installing engine - vehicles with four-wheel drive
  23
• 2 Assembly mountings
  26
• 2.1 Assembly overview - assembly mountings
  26
• Crankshaft group
  28
• 1 Cylinder block (pulley end)
  28
• 1.1 Assembly overview - cylinder block
  28
• 1.2 Assembly overview - poly V-belt drive with vane pump
  29
• 1.3 Assembly overview - poly V-belt drive with vane pump
  30
• 1.4 Removing and installing poly V-belt
  30
• 1.5 Renewing crankshaft oil seal on belt pulley end
  33
• 1.6 Removing and installing sealing flange on pulley end
  35
• 2 Cylinder block, gearbox end
  38
• 2.1 Assembly overview - cylinder block, gearbox end
  38
• 2.2 Removing and installing dual-mass flywheel
  39
• 2.3 Removing and installing sealing flange on gearbox side
  41
• 3 Crankshaft
  50
• 3.1 Assembly overview - crankshaft
  50
• 3.2 Renewing needle bearing in crankshaft
  51
• 3.3 Crankshaft dimensions
  52
• 4 Pistons and conrods
  53
• 4.1 Assembly overview - pistons and conrods
  53
• 4.2 Checking piston and cylinder bore
  54
• 4.3 Separating new conrod
  56
• 4.4 Measuring piston projection at TDC
  56
• 4.5 Cylinder head gasket identification
  58
• 4.6 Piston and cylinder dimensions
  58
• Cylinder head, valve gear
  59
• 1 Cylinder head
  59
• 1.1 Assembly overview - cylinder head
  59
• 1.2 Removing and installing cylinder head
  63
• 1.3 Removing and installing cylinder head cover
  67
• 1.4 Checking compression
  70
• 2 Toothed belt drive
  72
• 2.1 Assembly overview - toothed belt drive
  72
• 2.2 Removing and installing toothed belt
  73
• 2.3 Loosening and securing toothed belt
  90
• 3 Valve gear
  97
• 3.1 Assembly overview - valve gear
  97
• 3.2 Measuring axial play of camshaft
  99
• 3.3 Removing and installing camshaft
  99
• 3.4 Removing and installing camshaft oil seal
  104
• 3.5 Removing and installing valve stem seals
  105
• 4 Inlet and exhaust valves
  108
• 4.1 Checking valve guides
  108
• 4.2 Valve dimensions
  108
• Lubrication
  109
• 1 Sump, oil pump
  109
• 1.1 Assembly overview - sump and oil pump
  109
• 1.2 Removing and installing sump
  110
• 1.3 Engine oil
  112
• 1.4 Oil consumption measurement
  113
• 2 Oil filter, oil pressure switch
  114
• 2.1 Assembly overview - oil filter housing, oil pressure switch
  114
• 2.2 Checking oil pressure and oil pressure switch
  115
• 3 Oil circuit
  117
• 3.1 Assembly overview - oil supply line
  117
• 3.2 Removing and installing oil supply line
  117
• Cooling
  120
• 1 Cooling system, coolant
  120
• 1.1 Coolant hose schematic diagram
  120
• 1.2 Draining and filling coolant
  121
• 1.3 Checking cooling system for leaks
  123
• 1.4 Checking engine oil cooler for leaks
  125
• 2 Coolant pump, regulation of cooling system
  128
• 2.1 Assembly overview - coolant pump, thermostat
  128
• 2.2 Removing and installing coolant pump
  132
• 2.3 Removing and installing thermostat
  133
• 3 Coolant pipes
  136
• 3.1 Removing and installing rear coolant pipe for additional heater
  136
• 4 Radiator, radiator fan
  139
• 4.1 Assembly overview - radiator/radiator fan
  139
• 4.2 Removing and installing radiator
  141
• 4.3 Removing and installing fan support with fans
  142
• Turbocharging/supercharging
  144
• 1 Turbocharger
  144
• 1.1 Assembly overview - turbocharger, engine code BJB
  144
• 1.2 Assembly overview - turbocharger, engine codes BLS, BSU
  146
• 1.4 Removing and installing turbocharger
  154
• 1.5 Removing and installing turbocharger support with oil return pipe
  159
• 2 Charge air system
  162
• 2.1 Assembly overview - charge air system, engine code BJB
  162
• 2.2 Assembly overview - charge air system, engine codes BLS, BSU
  164
• 2.3 Fitting the charge-air system hose connections
  165
• 2.4 Checking charge air system for leaks
  166
• Mixture preparation - injection
  169
• 1 Injectors
  169
• 1.1 Assembly overview - unit injector
  169
• 1.2 Removing and installing O-rings for unit injector
  170
• 1.3 Removing and installing unit injector
  171
• 1.4 Removing and installing prewiring for unit injectors
  174
• 2 Vacuum system
  178
• 2.1 Connection overview
  178
• 2.2 Schematic diagram - vacuum system, engine code BJB
  178
• 2.3 Schematic diagram - vacuum system, engine codes BLS, BSU
  180
• 3 Air filter
  181
• 3.1 Assembly overview - air filter
  181
• 4 Intake manifold
  182
• 4.1 Assembly overview - intake manifold, engine code BJB
  182
• 4.2 Assembly overview - intake manifold, engine codes BLS, BSU
  182
• 4.3 Cleaning intake manifold flap connection, engine codes BLS, BSU
  183
• 5 Engine control unit
  185
• 5.1 Removing and installing engine control unit
  185
• 6 High-pressure pump
  187
• 6.1 Removing and installing fuel pump
  187
• Exhaust system
  193
• 1 Exhaust pipes, silencers
  193
• 1.1 Separating exhaust pipes, silencers
  193
• 1.2 Aligning exhaust system free of stress
  193
• 2 Emission control
  195
• 2.1 Assembly overview – emission control with catalytic converter
  195
• 2.3 Removing and installing particulate filter
  199
• 2.4 Removing and installing particulate filter - vehicles with four-wheel drive
  202
• 3 Exhaust gas temperature regulation
  206
• 3.1 Assembly overview - exhaust gas temperature regulation
  206
• 4 Exhaust gas recirculation system
  207
• 4.1 Assembly overview - exhaust gas recirculation system, engine code BJB
  207
• 4.2 Assembly overview - exhaust gas recirculation system, engine codes BLS, BSU
  208
• 4.3 Removing and installing exhaust gas recirculation cooler, engine codes BLS, BSU
  209
• 4.4 Checking mechanical exhaust gas recirculation valve, engine code BJB
  211
• Glow plug system
  212
• 1 Glow plug system
  212
• 1.1 Removing, installing and checking glow plugs
  212
• 1.2 Removing, installing and checking ceramic glow pin plugs
  213
• 1.3 Removing and installing engine speed sender G28
  215