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 Notes on removing
  3
• 1.2 Securing engine to assembly stand
  6
• 1.3 Notes on installing
  7
• 1.4 Assembly mountings
  9
• 1.5 Additional information and assembly work for vehicles with air conditioner
  10
• Crankshaft group
  12
• 1 Dismantling and assembling engine
  12
• 1.1 Assembly overview - poly V-belt drive
  12
• 1.2 Removing and installing poly V-belt
  14
• 1.3 Assembly overview - toothed belt drive
  15
• 1.4 Assembly overview - crankcase
  17
• 2 Sealing flange and flywheel
  19
• 2.1 Assembly overview - sealing flanges and flywheel
  19
• 2.2 Renewing crankshaft oil seal - pulley end
  21
• 2.3 Removing and installing sealing flange - pulley end
  23
• 2.4 Removing and installing drive plate
  27
• 3 Crankshaft
  29
• 3.1 Assembly overview - crankshaft
  29
• 3.2 Crankshaft dimensions
  30
• 3.3 Checking dowel pin projection out of crankshaft
  30
• 4 Pistons and conrods
  32
• 4.1 Assembly overview - pistons and conrods
  32
• 4.2 Piston and cylinder dimensions
  35
• 4.3 Checking piston projection at TDC
  35
• Cylinder head, valve gear
  37
• 1 Cylinder head
  37
• 1.1 Assembly overview - cylinder head
  37
• 1.2 Removing and installing cylinder head cover
  40
• 1.3 Removing, installing and tensioning toothed belt
  42
• 1.4 Removing and installing cylinder head
  55
• 1.5 Compression test
  59
• 2 Valve gear
  62
• 2.1 Assembly overview - valve gear
  62
• 2.2 Checking valve guides
  65
• 2.3 Renewing valve stem seals
  65
• 2.4 Removing and installing camshaft
  67
• 2.5 Removing and installing camshaft oil seal
  71
• Lubrication
  74
• 1 Engine oil
  74
• 1.1 Oil capacities
  74
• 1.2 Checking engine oil level
  74
• 2 Parts of lubrication system
  75
• 2.1 Assembly overview - oil pump, sump
  75
• 2.2 Removing and installing oil sump
  77
• 3 Oil filter bracket, oil pressure, engine oil cooler and oil supply line
  80
• 3.1 Assembly overview - oil filter bracket and engine oil cooler: Engine codes ANU, AUY, BVK
  80
• 3.3 Assembly overview - oil supply line to turbocharger
  83
• 3.4 Removing and installing oil supply line to turbocharger
  83
• 3.5 Checking oil pressure and oil pressure switch
  86
• Cooling
  88
• 1 Removing and installing parts of cooling system
  88
• 1.1 Assembly overview - cooling system, body side: Engine codes ANU, AUY, BVK
  89
• 1.2 Assembly overview - cooling system, body side: Engine codes ASZ, BTB
  91
• 1.3 Assembly overview - cooling system, engine side: Engine codes ANU, AUY, BVK
  92
• 1.5 Assembly overview - additional cooler
  95
• 1.6 Coolant hose schematic diagram: Engine code ANU
  97
• 1.7 Coolant hose schematic diagram: Engine codes AUY, BVK
  98
• 1.8 Coolant hose schematic diagram: Engine codes ASZ, BTB
  99
• 1.9 Draining and filling coolant
  100
• 1.10 Removing and installing radiator and fan
  103
• 1.11 Removing and installing coolant pump
  105
• 1.12 Removing and installing thermostat
  107
• 1.13 Checking cooling system for leaks
  109
• 1.14 Checking engine oil cooler for leaks
  111
• Fuel supply system
  114
• 1 Removing and installing parts of fuel supply system
  114
• 1.1 Safety precautions when working on fuel supply system
  115
• 1.2 Rules for cleanliness
  115
• 1.3 Assembly overview - fuel tank
  115
• 1.4 Assembly overview - fuel filter: Engine codes ANU, AUY, BVK
  117
• 1.5 Assembly overview - fuel filter: Engine codes ANU, ASZ, AUY, BTB, BVK
  119
• 1.6 Assembly overview - heat exchanger for fuel cooler
  120
• 1.7 Removing and installing fuel cooler: Engine codes ANU, AUY, BVK
  122
• 1.8 Emptying fuel tank
  123
• 1.9 Removing and installing fuel tank
  125
• 1.10 Removing and installing fuel delivery unit
  128
• 1.11 Removing and installing fuel gauge sender
  130
• 1.12 Checking fuel pump
  130
• 1.13 Checking tandem pump
  132
• 1.14 Removing and installing tandem pump
  136
• 1.15 Assembly overview - accelerator mechanism
  138
• Turbocharging/supercharging
  140
• 1 Charge air system with turbocharger
  140
• 1.1 Safety precautions
  141
• 1.2 Rules for cleanliness
  141
• 1.3 Hose connections with push-on connectors
  141
• 1.4 Assembly overview - turbocharger: Engine code ANU
  142
• 1.5 Assembly overview - turbocharger: Engine codes ASZ, BTB
  145
• 1.6 Assembly overview - turbocharger: Engine codes AUY, BVK
  147
• 1.7 Assembly overview - charge air cooling: Engine codes ANU, AUY, BVK
  149
• 1.8 Assembly overview - charge air cooler: Engine codes ASZ, BTB
  151
• 1.9 Checking charge air system for leaks
  152
• 1.10 Charge pressure control hose routing diagram: Engine code ANU
  153
• Mixture preparation - injection
  156
• 1 Repairing diesel direct injection system
  156
• 1.1 Safety precautions
  156
• 1.2 Rules for cleanliness
  157
• 1.3 General notes on injection
  157
• 1.4 Overview of fitting locations
  157
• 1.5 Assembly overview - intake manifold flap
  158
• 1.6 Assembly overview - air filter
  160
• 1.7 Assembly overview - unit injector
  160
• 1.8 Removing and installing O-rings for unit injector
  161
• 1.9 Removing and installing unit injector
  163
• 2 Engine control unit
  168
• 2.1 Reading and erasing engine control unit fault memory
  168
• 2.2 Removing and installing engine control unit
  169
• Exhaust system
  170
• 1 Removing and installing parts of exhaust system
  170
• 1.1 Assembly overview - front exhaust pipe with catalytic converter
  170
• 1.2 Assembly overview - silencers
  171
• 2 Exhaust gas recirculation system
  173
• 2.1 Assembly overview - exhaust gas recirculation: Engine code ANU
  173
• 2.3 Checking mechanical exhaust gas recirculation valve
  176
• Glow plug system
  177
• 1 Checking glow plug system
  177
• 1.1 Checking glow plugs
  178