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 Notes on removing
  4
• 1.2 Notes on installing
  8
• 1.3 Specified torques
  9
• 1.4 Front engine mounting
  10
• 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
  12
• 1.2 Removing and installing poly V-belt
  18
• 2 Sealing flange and flywheel or drive plate
  19
• 2.1 Assembly overview
  19
• 2.2 Renewing crankshaft oil seal - pulley end
  20
• 2.3 Removing and installing drive plate
  21
• 2.4 Removing and installing sealing flange - pulley end
  23
• 3 Crankshaft
  26
• 3.1 Assembly overview
  26
• 3.2 Pulling needle roller bearing out of and driving into crankshaft
  28
• 3.3 Crankshaft dimensions
  29
• 4 Pistons and conrods
  30
• 4.1 Assembly overview
  30
• 4.2 Separating new conrods
  31
• 4.3 Pistons and cylinders
  32
• 4.4 Checking piston projection at TDC
  33
• 4.5 Piston and cylinder dimensions
  34
• Cylinder head, valve gear
  35
• 1 Cylinder head
  35
• 1.1 Assembly overview
  35
• 1.2 Removing, installing and tensioning toothed belt
  37
• 1.3 Removing and installing cylinder head
  48
• 1.4 Checking compression
  51
• 2 Repairing valve gear
  54
• 2.1 Assembly overview - valve gear
  54
• 2.2 Reworking valve seats
  57
• 2.3 Checking valve guides
  58
• 2.4 Renewing valve stem seals
  59
• 2.5 Removing and installing camshaft
  60
• 2.6 Removing and installing camshaft oil seal
  63
• Lubrication
  66
• 1 Parts of lubrication system
  66
• 1.1 Engine oil
  66
• 1.2 Assembly overview - parts of lubrication system
  67
• 1.3 Assembly overview - oil filter bracket
  69
• 1.4 Removing and installing oil sump
  70
• 1.5 Checking oil pressure and oil pressure switch
  75
• Cooling
  78
• 1 Parts of cooling system
  78
• 1.1 Assembly overview - parts of cooling system, body side
  78
• 1.2 Assembly overview - parts of cooling system, engine side
  82
• 1.3 Draining and filling coolant
  87
• 1.4 Removing and installing radiator
  90
• 1.5 Removing and installing coolant pump
  92
• 1.6 Removing and installing thermostat
  94
• 1.7 Removing and installing viscous fan coupling
  96
• 1.8 Check fuel cooling pump V166
  97
• 1.9 Check radiator fan V7
  98
• Fuel supply system
  101
• 1 Parts of fuel supply system
  101
• 1.1 Safety precautions when working on fuel supply system
  101
• 1.2 Rules for cleanliness
  101
• 1.4 Assembly overview - fuel filter
  106
• 1.5 Fuel and coolant hose schematic diagram
  109
• 1.6 Removing and installing fuel cooler
  110
• 1.7 Removing and installing fuel tank
  111
• 1.8 Removing and installing fuel pump
  112
• 1.9 Removing and installing suction-jet pump
  115
• 1.10 Checking fuel pump
  117
• 1.11 Removing and installing fuel delivery unit
  117
• 1.12 Removing and installing fuel gauge sender
  122
• 1.13 Assembly overview - accelerator mechanism
  122
• 1.14 Adjust accelerator position sender
  124
• 1.15 Removing and installing tandem pump
  125
• 1.16 Checking tandem pump
  128
• Turbocharging/supercharging
  132
• 1 Charge air system with turbocharger
  132
• 1.1 Assembly overview - turbocharger with attachments
  132
• 1.2 Removing and installing parts of charge air cooling
  134
• 1.3 Vacuum hose schematic diagram
  138
• 1.4 Rules for cleanliness
  138
• Mixture preparation - injection
  140
• 1 Repairing diesel direct injection system
  140
• 1.1 Safety precautions
  140
• 1.2 Rules for cleanliness
  140
• 1.3 Overview of fitting locations
  141
• 1.4 Assembly overview - intake manifold flap
  143
• 1.5 Assembly overview - unit injector
  143
• 1.6 Removing and installing O-rings for unit injector
  144
• 1.7 Removing and installing unit injector
  146
• 2 Engine control unit
  151
• 2.1 Reading and clearing engine control unit event memory
  151
• 2.2 Adapting functions and components
  152
• 2.3 Removing and installing engine control unit
  153
• Exhaust system
  155
• 1 Parts of the exhaust system
  155
• 1.1 Assembly overview - four-wheel drive vehicles
  155
• 1.2 Assembly overview - front-wheel drive vehicles
  157
• 2 Exhaust gas recirculation system
  159
• 2.1 Assembly overview - parts of exhaust gas recirculation
  159
• 2.2 Checking exhaust gas recirculation valve (mechanical)
  163
• Glow plug system
  165
• 1 Checking glow plug system
  165
• 1.1 Checking glow plugs
  165