4-cylinder diesel engine with distributor-type injection pump

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
  2
• 1.2 Notes on installing
  3
• 1.3 Specified torques
  4
• 1.4 Front engine mounting
  4
• 1.5 Additional notes and assembly work for vehicles with air conditioner
  5
• Crankshaft group
  6
• 1 Dismantling and assembling engine
  6
• 1.1 Assembly overview - toothed belt drive
  7
• 1.2 Cylinder head with attachments
  8
• 1.3 Assembly overview - crankcase
  9
• 1.4 Removing and installing poly V-belt
  10
• 1.5 Removing, installing and tensioning toothed belt
  11
• 1.6 Checking semi-automatic toothed belt tensioning roller
  20
• 2 Removing and installing sealing flanges and flywheel or drive plate
  21
• 2.1 Renewing crankshaft oil seal - belt pulley end
  22
• 2.2 Removing and installing drive plate
  23
• 3 Removing and installing crankshaft
  25
• 3.1 Crankshaft dimensions
  26
• 4 Dismantling and assembling pistons and conrods
  27
• 4.1 Separating new conrods
  29
• 4.2 Checking piston projection at TDC
  30
• 4.3 Piston and cylinder dimensions
  31
• Cylinder head, valve gear
  32
• 1 Removing and installing cylinder head
  32
• 1.1 Installing cylinder head
  34
• 1.2 Checking compression
  35
• 2 Repairing valve gear
  37
• 2.1 Reworking valve seats
  39
• 2.2 Checking valve guides
  40
• 2.3 Renewing valve guides
  41
• 2.4 Renewing valve stem seals
  42
• 2.5 Removing and installing camshaft
  43
• 2.6 Checking hydraulic bucket tappets
  45
• Lubrication
  47
• 1 Engine oil
  47
• 1.1 Oil capacities
  47
• 1.2 Engine oil specifications:
  47
• 1.3 Parts of lubrication system
  47
• 1.4 Checking oil pressure and oil pressure switch
  52
• Cooling
  53
• 1 Removing and installing parts of cooling system
  53
• 1.1 Parts of cooling system - body side
  53
• 1.2 Parts of cooling system - engine side
  55
• 1.3 Removing and installing coolant pump and compact bracket
  56
• 1.4 Coolant hose schematic diagram
  58
• 1.5 Draining and filling coolant
  58
• 1.6 Removing and installing radiator
  60
• 1.7 Removing and installing viscous fan coupling
  62
• Fuel supply system
  63
• 1 Removing and installing parts of fuel supply system
  63
• 1.1 Removing and installing fuel tank with attachments
  63
• 1.2 Repairing fuel filter
  69
• 1.3 Safety precautions when working on fuel supply system
  70
• 1.4 Rules for cleanliness
  70
• 1.5 Removing and installing fuel tank
  70
• 1.6 Removing and installing fuel pump
  71
• 1.7 Checking fuel pump
  73
• 1.8 Repairing accelerator mechanism
  74
• 1.9 Adjusting accelerator position sender G79
  75
• Turbocharging/supercharging
  77
• 1 Charge air system with turbocharger
  77
• 1.1 Safety precautions
  77
• 1.2 Rules for cleanliness
  77
• 1.3 Removing and installing turbocharger with attachments
  77
• 1.4 Removing and installing parts of charge air cooling
  82
• 1.5 Charge pressure control hose routing diagram, engine code AFN ▸ 08.97
  84
• 1.7 Charge pressure control hose routing diagram, engine code AHU ▸ 08.97
  86
• 1.8 Charge pressure control hose routing diagram, engine code AHU 09.97 ▸
  88
• 2 Checking charge pressure system
  89
• 2.1 Checking vacuum unit for charge pressure control valve
  89
• 2.2 Removing and installing vacuum unit for charge pressure regulating valve
  89
• 2.3 Checking turbocharger
  90
• Mixture preparation - injection
  91
• 1 Repairing diesel direct injection system
  91
• 1.1 Safety precautions
  91
• 1.2 Rules for cleanliness
  92
• 1.3 Fitting locations overview
  92
• 1.4 Injection pump with one-piece injection pump pulley
  94
• 1.5 Injection pump with two-piece injection pump pulley
  96
• 1.6 Setting engine to TDC No. 1 cylinder, engine removed
  98
• 1.7 Removing and installing injection pump
  99
• 1.8 Dynamically checking and adjusting commencement of injection
  109
• 1.9 Removing and installing injectors
  112
• 1.10 Repairing injectors
  114
• 1.11 Sealing injection pump
  115
• 2 Engine control unit
  120
• 2.1 Reading and clearing engine control unit fault memory
  120
• 2.2 Adapting functions and components
  121
• 2.3 Removing and installing engine control unit
  122
• Exhaust system
  123
• 1 Parts of exhaust system
  123
• 1.1 Removing and installing parts of exhaust system
  123
• 2 Exhaust gas recirculation system
  126
• 2.1 Removing and installing parts of exhaust gas recirculation system
  126
• 2.2 Vacuum hose schematic diagram
  127
• 2.3 Checking exhaust gas recirculation valve
  127
• Glow plug system
  129
• 1 Checking glow plug system
  129
• 1.1 Checking glow plugs
  130