4-cylinder diesel engine with unit injector

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Engine number
  1
• 1.2 Engine data
  1
• Removing and installing engine
  3
• 1 Removing and installing engine
  3
• 1.1 Removing engine
  4
• 1.2 Securing engine to assembly stand
  7
• 1.3 Notes on installing
  7
• 1.4 Specified torques
  8
• 1.5 Aligning engine and gearbox mountings
  8
• 1.6 Specified torques for assembly mountings
  9
• 1.7 Additional information and removal instructions for vehicles with air conditioner
  10
• Crankshaft group
  12
• 1 Dismantling and assembling engine
  12
• 1.1 Overview
  12
• 1.2 Removing and installing poly V-belt
  16
• 2 Removing and installing sealing flanges and flywheel or drive plate
  18
• 2.1 Renewing crankshaft oil seal - pulley end
  19
• 2.2 Removing and installing drive plate
  20
• 2.3 Removing and installing sealing flange - pulley end
  22
• 3 Removing and installing crankshaft
  25
• 3.1 Crankshaft dimensions
  26
• 4 Dismantling and assembling pistons and conrods
  27
• 4.1 Separating new conrod
  30
• 4.2 Checking piston projection at TDC
  30
• 4.3 Piston and cylinder dimensions
  32
• Cylinder head, valve gear
  33
• 1 Assembly overview - cylinder head
  33
• 1.1 Removing and installing cylinder head cover
  36
• 1.2 Removing, installing and tensioning toothed belt
  37
• 1.3 Removing and installing cylinder head
  49
• 1.4 Checking compression
  53
• 2 Assembly overview - valve gear
  56
• 2.1 Checking valve guides
  58
• 2.2 Renewing valve stem seals
  59
• 2.3 Removing and installing camshaft
  60
• 2.4 Removing and installing camshaft oil seal
  64
• Lubrication
  67
• 1 Removing and installing parts of lubrication system
  67
• 1.1 Engine oil
  67
• 1.2 Checking engine oil level
  67
• 1.3 Removing and installing parts of lubrication system
  67
• 1.4 Removing and installing sump
  72
• 1.5 Checking oil pressure and oil pressure switch
  74
• Cooling
  77
• 1 Removing and installing parts of cooling system
  77
• 1.1 Parts of cooling system - body side
  77
• 1.2 Parts of cooling system - engine side
  79
• 1.3 Coolant hose schematic diagram
  80
• 1.4 Draining and filling coolant
  85
• 1.5 Removing and installing radiator
  88
• 1.6 Removing and installing coolant pump
  90
• 1.7 Removing and installing thermostat
  92
• 1.8 Checking cooling system for leaks
  94
• 1.9 Checking oil cooler for leaks
  95
• Fuel supply system
  98
• 1 Removing and installing parts of fuel supply system
  98
• 1.1 Assembly overview - fuel tank with attachments
  98
• 1.2 Assembly overview - fuel filter
  105
• 1.3 Safety precautions when working on fuel supply system
  107
• 1.4 Rules for cleanliness
  107
• 1.5 Removing and installing fuel cooler
  107
• 1.6 Removing and installing fuel tank
  108
• 1.7 Removing and installing fuel delivery unit
  110
• 1.8 Removing and installing fuel gauge sender
  112
• 1.9 Removing and installing fuel pump
  113
• 1.10 Checking fuel pump
  114
• 1.11 Removing, installing and checking suction jet pump
  116
• 1.12 Assembly overview - accelerator mechanism
  118
• 1.13 Checking tandem pump
  119
• 1.14 Removing and installing tandem pump
  122
• Turbocharging/supercharging
  125
• 1 Charge air system with turbocharger
  125
• 1.1 Assembly overview - turbocharger with attachments
  125
• 1.2 Removing and installing parts of charge air cooling
  130
• 1.3 Checking charge air system for leaks
  133
• 1.4 Vacuum hose schematic diagram
  135
• 1.5 Rules for cleanliness
  137
• 1.6 Safety precautions
  138
• Mixture preparation - injection
  139
• 1 Repairing diesel direct injection system
  139
• 1.1 Safety precautions
  139
• 1.2 Rules for cleanliness
  139
• 1.3 Fitting locations overview
  140
• 1.4 Assembly overview - Intake manifold flap
  145
• 1.5 Assembly overview - unit injector
  146
• 1.6 Removing and installing O-rings for unit injector
  148
• 1.7 Removing and installing unit injector
  149
• 2 Checking additional signals
  155
• 2.1 Checking speed signal
  155
• 3 Engine control unit
  156
• 3.1 Removing and installing engine control unit
  156
• 3.2 Reading and clearing engine control unit fault memory
  156
• 3.3 Adapting components
  157
• Exhaust system
  159
• 1 Removing and installing parts of exhaust system
  159
• 1.1 Front-wheel drive vehicles
  159
• 1.2 Vehicles with four-wheel drive
  162
• 2 Exhaust gas recirculation system
  167
• 2.1 Removing and installing parts of exhaust gas recirculation system
  167
• Glow plug system
  172
• 1 Glow plug system
  172
• 1.1 Checking glow plug system
  172
• 1.2 Checking glow plugs
  173