4-cylinder diesel engine (common rail)

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Engine number and cylinder 1
  1
• 1.2 Engine data
  1
• Self-diagnosis
  2
• 1 Self-diagnosis
  2
• 1.1 Features of self-diagnosis
  2
• 1.2 Technical data of self-diagnosis
  2
• 1.3 Connecting the fault reader
  3
• 2 Fault memory
  7
• 2.1 Reading event memory
  7
• 2.2 Clearing event memory
  8
• 3 Fault table: SAE P0 codes
  9
• 4 Fault table: SAE P1 codes
  12
• 5 Final control diagnosis
  26
• 5.1 Performing final control diagnosis
  26
• 6 Measured value blocks
  29
• 6.1 Reading measured value block
  29
• 6.2 Evaluating measured value blocks at idling speed and ignition on
  30
• 6.3 Evaluating measured value blocks at full throttle
  38
• Removing and installing engine
  44
• 1 Removing and installing engine
  44
• 1.1 Notes on removing
  46
• 1.2 Securing engine to assembly stand
  49
• 1.3 Notes on installing
  50
• 1.4 Specified torques
  51
• Crankshaft group
  52
• 1 Dismantling and assembling engine
  52
• 1.1 Part I
  53
• 1.2 Part II
  54
• 1.3 Part III
  55
• 2 Poly V-belt drive
  57
• 2.1 Removing and installing poly-V belt
  57
• 3 Crankshaft sprockets and dual mass flywheel
  60
• 3.1 Removing and installing crankshaft sprockets and dual mass flywheel
  61
• 3.2 Checking camshaft sprockets, adjusting if necessary
  64
• 3.3 Renewing crankshaft sprocket
  67
• 3.4 Renewing the dual mass flywheel needle bearing
  69
• 3.5 Renewing crankshaft oil seal - pulley end
  71
• 3.6 Renewing crankshaft oil seal -flywheel end-
  73
• 4 Removing and installing crankshaft
  77
• 4.1 Crankshaft dimensions
  78
• 5 Dismantling and assembling pistons and conrods
  79
• 5.1 Cylinder dimension
  81
• Cylinder head, valve gear
  83
• 1 Cylinder head
  83
• 1.1 Removing and installing cylinder head
  86
• 1.2 Checking compression
  88
• 2 Repairing valve gear
  90
• 2.1 Checking valve guides
  93
• 2.2 Removing and installing rocker fingers
  93
• 2.3 Renewing valve stem seals
  94
• 2.4 Removing and installing camshaft
  96
• 2.5 Checking and adjusting valve clearance
  99
• Lubrication
  101
• 1 Removing and installing parts of lubrication system
  101
• 1.1 Engine oil:
  101
• 1.2 Checking oil pressure and oil pressure switch
  106
• Cooling
  108
• 1 Removing and installing parts of cooling system
  108
• 1.1 Parts of cooling system, body side
  108
• 1.2 Parts of cooling system - engine side
  111
• 1.3 Draining and adding coolant
  112
• 1.4 Removing and installing radiator
  114
• 1.5 Removing and installing viscous fan
  115
• Fuel supply system
  116
• 1 Removing and installing parts of fuel supply system
  116
• 1.1 Removing and installing fuel tank with attached components
  116
• 1.2 Safety regulations for working on fuel supply
  118
• 1.3 Rules for cleanliness
  118
• 1.4 Emptying fuel tank
  118
• 1.5 Removing and installing fuel tank
  119
• 1.6 Repairing fuel filter
  122
• 1.7 Removing and installing fuel delivery unit
  122
• 1.8 Checking fuel system pressurisation pump G6
  123
• 1.9 Repairing accelerator mechanism
  126
• 1.10 Checking adjustment of accelerator position sender
  127
• 1.11 Checking accelerator position sender G79
  128
• Turbocharging/supercharging
  131
• 1 Charge air system with turbocharger
  131
• 1.1 Removing and installing turbocharger with attachments
  131
• 1.2 Removing and installing parts of charge air cooling
  132
• 1.3 Rules for cleanliness
  132
• 1.4 Removing and installing turbocharger
  133
• 1.5 Vacuum hose connection diagram
  135
• 2 Boost pressure regulation
  137
• 2.1 Checking charge pressure control
  137
• Mixture preparation - injection
  141
• 1 Repairing diesel direct injection system
  141
• 1.1 Safety precautions
  141
• 1.2 Rules for cleanliness
  142
• 1.3 Overview of fitting locations
  142
• 1.4 System layout
  144
• 1.5 Removing and installing high-pressure pump
  144
• 1.6 Removing and installing injector
  147
• 2 Checking components and functions
  150
• 2.1 Checking voltage supply for diesel direct injection system
  150
• 2.2 Checking engine speed sender G28
  150
• 2.3 Checking intake manifold pressure sender G71 and intake manifold temperature sender G72
  151
• 2.4 Checking coolant temperature sender G62
  153
• 2.5 Checking intake manifold temperature sender G72
  155
• 2.6 Checking fuel pressure sender G247
  157
• 2.7 Checking air mass meter G70
  158
• 2.8 Checking intake manifold flap changeover
  160
• 2.9 Checking camshaft position Hall sender G40
  162
• 2.10 Checking injectors
  163
• 2.11 Checking fuel pressure regulating valve N276
  164
• 3 Checking additional signals
  166
• 3.1 Checking speed signal
  166
• 3.2 Checking signals from and to air conditioning system
  167
• 3.3 Checking speed signal
  168
• 3.4 Checking signal from brake light switch F and brake light switch F47
  168
• 3.5 Checking signal from clutch pedal switch F36
  169
• 4 Renewing, coding and matching engine control unit
  171
• 4.1 Renewing diesel direct injection system control unit J248
  171
• 4.2 Coding engine control unit
  172
• 4.3 Activating maximum speed governor in engine electronics control unit
  173
• 4.4 Adapting working speed governor
  175
• 4.5 Activating cruise control system
  177
• Exhaust system
  179
• 1 Removing and installing parts of exhaust system
  179
• 2 Exhaust gas recirculation system
  180
• 2.1 Removing and installing parts of exhaust gas recirculation system
  180
• 2.2 Checking exhaust gas recirculation valve
  181
• 2.3 Checking exhaust gas recirculation system
  181
• Glow plug system
  185
• 1 Checking glow plug system
  185