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
  3
• 1.2 Securing engine to assembly stand
  14
• 1.3 Installing engine
  16
• 1.4 Checking and adjusting assembly mountings
  18
• 1.5 Assembly mountings- specified torques
  22
• Crankshaft group
  24
• 1 Dismantling and assembling engine
  24
• 1.1 Assembly overview
  24
• 1.2 Assembly overview - toothed belt drive
  26
• 1.3 Assembly overview - poly V-belt drive
  27
• 1.4 Assembly overview - cylinder block
  28
• 1.5 Removing and installing poly V-belt
  29
• 1.6 Removing and installing engine support
  31
• 2 Removing and installing sealing flange and flywheel
  36
• 2.1 Assembly overview - sealing flanges and flywheel
  36
• 2.2 Renewing crankshaft oil seal - pulley end
  38
• 2.3 Removing and installing sealing flange - pulley end
  40
• 2.4 Renewing crankshaft sealing flange - flywheel end
  42
• 2.5 Removing and installing dual-mass flywheel
  50
• 3 Crankshaft
  53
• 3.1 Assembly overview - crankshaft
  53
• 3.2 Crankshaft dimensions
  54
• 3.3 Identification of crankshaft upper bearing
  54
• 3.4 Pulling needle bearing out of and driving into crankshaft
  54
• 4 Pistons and conrods
  57
• 4.1 Assembly overview - pistons and conrods
  57
• 4.2 Separating new conrod
  58
• 4.3 Checking piston projection at TDC
  59
• 4.4 Piston and cylinder dimensions
  60
• 4.5 Piston rings, cylinder bore and piston installation position
  60
• Cylinder head, valve gear
  63
• 1 Cylinder head
  63
• 1.1 Assembly overview - cylinder head
  63
• 1.2 Removing and installing cylinder head cover
  66
• 1.3 Removing, installing and tensioning toothed belt
  68
• 1.4 Removing and installing cylinder head
  84
• 1.5 Checking compression
  90
• 2 Valve gear
  93
• 2.1 Assembly overview - valve gear
  93
• 2.2 Checking axial clearance of camshaft
  95
• 2.3 Sealing parting surfaces of bearing caps 1 and 5
  96
• 2.4 Valve dimensions
  96
• 2.5 Checking valve guides
  96
• 2.6 Renewing valve stem seals
  97
• 2.7 Removing and installing camshaft
  98
• 2.8 Removing and installing camshaft oil seal
  102
• Lubrication
  104
• 1 Engine oil
  104
• 1.1 Engine oil specifications
  104
• 1.2 Oil capacities
  104
• 1.3 Checking engine oil level
  104
• 2 Parts of lubrication system
  105
• 2.1 Assembly overview, engine codes BKC, BLS, BXE - oil pump, sump
  105
• 2.2 Assembly overview, engine code BRM - oil pump, sump
  107
• 2.3 Removing and installing oil sump
  109
• 2.4 Removing and installing oil pump
  112
• 3 Oil filter bracket, oil pressure, oil cooler and oil supply line
  114
• 3.1 Assembly overview - oil filter bracket and oil cooler
  114
• 3.2 Removing and installing oil filter bracket together with oil cooler
  115
• 3.3 Checking oil pressure and oil pressure switch
  120
• 3.4 Assembly overview - oil supply line to turbocharger
  121
• 3.5 Removing and installing oil supply line to turbocharger
  122
• Cooling
  126
• 1 Parts of cooling system
  126
• 1.1 Parts of cooling system on body side, engine codes BLS, BRM
  127
• 1.2 Parts of cooling system on body side, engine codes BKC, BXE
  129
• 1.3 Parts of cooling system on engine side, engine codes BLS, BRM
  130
• 1.4 Parts of cooling system on engine side, engine codes BKC, BXE
  132
• 1.5 Coolant hose schematic diagram
  134
• 1.6 Draining and filling coolant
  140
• 1.7 Removing and installing radiator fan V7 and radiator fan 2 V177
  144
• 1.8 Removing and installing radiator
  145
• 1.9 Removing and installing coolant pump
  147
• 1.10 Removing and installing thermostat
  149
• 1.11 Checking cooling system for leaks
  151
• 1.12 Checking oil cooler for leaks
  153
• Fuel supply system
  156
• 1 Safety precautions when working on fuel supply system
  156
• 2 Rules for cleanliness
  157
• 3 Fuel tank, vehicles with front-wheel drive
  158
• 3.1 Assembly overview - fuel tank
  158
• 3.2 Emptying fuel tank
  160
• 3.3 Removing and installing fuel tank
  162
• 3.4 Removing and installing fuel delivery unit
  164
• 3.5 Removing and installing fuel gauge sender
  167
• 3.6 Checking fuel pump
  168
• 4 Fuel tank, vehicles with four-wheel drive
  171
• 4.1 Assembly overview - fuel tank
  171
• 4.2 Emptying fuel tank
  172
• 4.3 Removing and installing fuel tank
  174
• 4.4 Removing and installing fuel gauge sender 2 -G169-
  178
• 4.5 Removing and installing suction-jet pump
  179
• 4.6 Checking fuel pump
  179
• 5 Repairing fuel supply system
  182
• 5.1 Assembly overview - fuel filter
  182
• 5.2 Removing and installing fuel cooler
  183
• 5.3 Checking tandem pump
  184
• 5.4 Removing and installing tandem pump
  189
• 6 Electronic power control (EPC)
  194
• 6.1 Function of EPC system
  194
• 6.2 Assembly overview - accelerator module
  194
• 6.3 Removing and installing accelerator module
  195
• Turbocharging/supercharging
  197
• 1 Charge air system with turbocharger
  197
• 1.1 Safety precautions
  197
• 1.2 Rules for cleanliness
  197
• 2 Charge air system with turbocharger, engine codes BKC, BXE
  199
• 2.1 Assembly overview - turbocharger (engine codes BKC, BXE)
  199
• 2.2 Removing and installing turbocharger, engine codes BKC, BXE
  201
• 2.3 Assembly overview - parts of charge air cooling (engine codes BKC, BXE)
  207
• 3 Charge air system with turbocharger, engine codes BLS, BRM
  209
• 3.1 Assembly overview \- turbocharger (engine codes BLS (without diesel particulate filter), BRM)
  209
• 4 Hose connections
  233
• 4.1 Hose connections
  233
• 5 Removing and installing charge air cooler
  235
• 5.1 Removing and installing charge air cooler
  235
• 6 Checking charge air system for leaks
  237
• 7 Vacuum hose schematic diagram
  239
• 7.1 Vehicles with engine codes BKC, BXE
  239
• 7.2 Vehicles with engine codes BLS, BRM
  240
• Mixture preparation - injection
  241
• 1 Diesel direct injection system
  241
• 1.1 Safety precautions
  242
• 1.2 Rules for cleanliness
  243
• 1.3 Overview of fitting locations
  244
• 1.4 Assembly overview - unit injector
  250
• 1.5 Removing and installing unit injector
  252
• 1.6 Removing and installing O-rings for unit injector
  255
• 1.7 Assembly overview - intake manifold
  256
• 1.8 Removing and installing intake manifold
  259
• 1.11 Removing and installing intake manifold flap motor V157
  268
• 1.12 Assembly overview - air filter
  270
• 1.13 Removing and installing engine speed sender G28
  271
• 1.14 Removing and installing sender wheel for engine speed sender G28
  273
• 1.15 Removing and installing automatic glow period control unit J179
  273
• 2 Engine control unit
  277
• 2.1 Reading and erasing engine control unit fault memory
  277
• 2.2 Adapting functions and components
  278
• 2.3 Removing and installing engine control unit
  279
• Exhaust system
  283
• 1 Exhaust system
  283
• 1.1 Assembly overview - parts of the exhaust system
  285
• 1.2 Removing and installing front exhaust pipe
  291
• 1.3 Separating and joining front and rear silencers
  296
• 1.4 Aligning exhaust system free of stress
  297
• 2 Exhaust gas recirculation system
  299
• 2.1 Assembly overview - parts of exhaust gas recirculation
  299
• 2.2 Assembly overview - parts of exhaust gas recirculation cooler (engine codes BLS, BRM)
  302
• 2.3 Removing and installing exhaust gas recirculation cooler
  303
• 2.4 Checking mechanical exhaust gas recirculation valve, engine codes BKC, BXE
  309
• Glow plug system
  311
• 1 Checking glow plug system
  311
• 1.1 Testing, removing and installing glow plugs
  311