4-cylinder diesel engine (1.9 l engine)

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Engine number
  1
• 1.2 Engine data
  1
• Removing and installing engine
  2
• 1 Removing and installing engine
  2
• 1.1 Removing engine
  2
• 1.2 Securing engine to assembly stand
  8
• 1.3 Notes on installing
  9
• 1.4 Assembly mountings
  10
• Crankshaft group
  12
• 1 Dismantling and assembling engine
  12
• 1.1 Assembly overview - poly V-belt drive
  13
• 1.2 Removing and installing poly V-belt
  13
• 1.3 Assembly overview - toothed belt drive
  16
• 1.4 Assembly overview - crankcase
  20
• 2 Removing and installing sealing flange and flywheel
  21
• 2.1 Assembly overview - sealing flanges and flywheel
  21
• 2.2 Renewing crankshaft oil seal - pulley end
  22
• 2.3 Removing and installing sealing flange - pulley end
  25
• 2.4 Renewing crankshaft sealing flange - flywheel end
  27
• 2.5 Removing and installing engine speed sender G28
  34
• 3 Crankshaft
  36
• 3.1 Assembly overview - crankshaft
  36
• 3.2 Crankshaft dimensions
  41
• 4 Pistons and conrods
  42
• 4.1 Assembly overview - pistons and conrods
  42
• 4.2 Separating new conrods
  45
• 4.3 Checking piston projection at TDC
  45
• 4.4 Piston and cylinder dimensions
  47
• Cylinder head, valve gear
  48
• 1 Cylinder head
  48
• 1.1 Assembly overview - cylinder head
  49
• 1.2 Removing and installing cylinder head cover
  52
• 1.3 Removing, installing and tensioning toothed belts
  54
• 1.4 Removing and installing cylinder head
  70
• 1.5 Checking compression
  75
• 2 Valve gear
  77
• 2.1 Assembly overview - valve gear
  77
• 2.2 Checking valve guides
  79
• 2.3 Renewing valve stem seals
  81
• 2.4 Removing and installing camshaft
  83
• 2.5 Removing and installing camshaft oil seal
  87
• Lubrication
  89
• 1 Engine oil
  89
• 1.1 Oil capacities
  89
• 1.2 Checking engine oil level
  89
• 1.3 Checking engine oil level
  89
• 2 Parts of lubrication system
  90
• 2.1 Assembly overview - oil pump, sump
  90
• 2.2 Removing and installing sump
  91
• 3 Oil filter bracket, oil pressure, engine oil cooler and oil supply line
  95
• 3.1 Assembly overview - oil filter bracket and engine oil cooler
  95
• 3.2 Checking oil pressure and oil pressure switch
  96
• 3.3 Assembly overview - oil supply line to turbocharger
  97
• 3.4 Removing and installing oil supply line to turbocharger
  98
• Cooling
  100
• 1 Parts of cooling system
  100
• 1.1 Assembly overview - parts of cooling system, body side
  101
• 1.3 Assembly overview - cooling system, engine side
  103
• 1.4 Coolant hose schematic diagram
  105
• 1.5 Draining and filling with coolant
  106
• 1.6 Removing and installing fan support with fans
  108
• 1.7 Removing and installing radiator
  110
• 1.8 Removing and installing coolant pump
  112
• 1.9 Removing and installing thermostat
  114
• 1.10 Checking cooling system for leaks
  116
• 1.11 Checking engine oil cooler for leaks
  118
• Fuel supply system
  120
• 1 Safety precautions when working on fuel supply system
  120
• 2 Rules for cleanliness
  121
• 3 Parts of fuel supply system
  122
• 3.1 Assembly overview - fuel tank
  123
• 3.2 Assembly overview - fuel filter
  125
• 3.3 Removing and installing fuel cooler
  126
• 3.4 Emptying fuel tank
  126
• 3.5 Removing and installing fuel tank
  130
• 3.6 Removing and installing fuel delivery unit
  132
• 3.7 Removing and installing fuel gauge sender
  135
• 3.8 Checking fuel pump
  135
• 3.9 Assembly overview - accelerator mechanism
  141
• 3.10 Checking tandem pump
  142
• 3.11 Removing and installing tandem pump
  146
• Turbocharging/supercharging
  150
• 1 Charge air system with turbocharger
  150
• 1.1 Safety precautions
  150
• 1.2 Rules for cleanliness
  150
• 1.3 Hose connections
  151
• 1.4 Assembly overview - turbocharger
  152
• 1.5 Removing and installing turbocharger
  156
• 1.6 Assembly overview - charge air cooling
  158
• 1.7 Vacuum hose schematic diagram
  161
• 1.8 Checking charge air system for leaks
  162
• Mixture preparation - injection
  165
• 1 Diesel direct injection system
  165
• 1.1 Safety precautions
  165
• 1.2 Rules for cleanliness
  166
• 1.3 Assembly overview - unit injector
  166
• 1.4 Removing and installing unit injector
  168
• 1.5 Adjusting non-contact gap of unit injectors
  170
• 1.6 Removing and installing O-rings for unit injector
  171
• 1.7 Assembly overview - intake manifold
  172
• 1.8 Assembly overview - air filter
  175
• 2 Engine control unit
  176
• 2.1 Reading and erasing engine control unit fault memory
  176
• 2.2 Removing and installing engine control unit
  177
• 2.3 Removing and installing anti-theft engine control unit
  178
• Exhaust system
  182
• 1 Exhaust system
  182
• 1.1 Assembly overview - front exhaust pipe with catalytic converter
  183
• 1.2 Assembly overview - front exhaust pipe with particulate filter
  184
• 1.3 Assembly overview - silencers
  186
• 1.4 Aligning exhaust system free of stress
  187
• 2 Exhaust gas recirculation system
  188
• 2.1 Assembly overview - exhaust gas recirculation
  188
• 2.2 Checking mechanical exhaust gas recirculation valve
  190
• 2.3 Vacuum hose schematic diagram on solenoid valve block
  191
• Glow plug system
  192
• 1 Checking glow plug system
  192
• 1.1 Checking glow plugs
  192
• 1.2 Characteristics of ceramic glow plugs
  193