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
  2
• 1 Removing and installing engine
  2
• 1.1 Removing engine
  2
• 1.2 Securing engine to assembly stand
  6
• 1.3 Notes on installing
  7
• 1.4 Assembly mountings
  8
• 1.5 Additional notes and assembly work for vehicles with air conditioner
  9
• Crankshaft group
  10
• 1 Dismantling and assembling engine
  10
• 1.1 Assembly overview - toothed belt drive
  10
• 1.2 Assembly overview - poly V-belt drive
  11
• 1.3 Removing and installing poly V-belt
  13
• 1.4 Assembly overview - crankcase
  15
• 2 Sealing flange and flywheel
  17
• 2.2 Assembly overview - sealing flange and flywheel, engine code BMT
  19
• 2.3 Renewing crankshaft oil seal - belt pulley end
  20
• 2.4 Removing and installing sealing flange - belt pulley end
  21
• 2.5 Renewing crankshaft sealing flange - flywheel end, engine code BMT
  23
• 2.6 Removing and installing engine speed sender G28 , engine code BMT
  30
• 3 Crankshaft
  32
• 3.1 Assembly overview - crankshaft
  32
• 3.2 Crankshaft dimensions
  33
• 4 Pistons and conrods
  35
• 4.1 Assembly overview - pistons and conrods
  35
• 4.2 Separating new conrods
  36
• 4.3 Checking pistons, piston rings and cylinder bores
  37
• 4.4 Checking piston projection at TDC
  38
• 4.5 Piston and cylinder dimensions
  40
• Cylinder head, valve gear
  41
• 1 Cylinder head
  41
• 1.1 Assembly overview - cylinder head
  41
• 1.2 Removing and installing cylinder head cover
  44
• 1.3 Removing, installing and tensioning toothed belt
  45
• 1.4 Removing and installing cylinder head
  54
• 1.5 Checking compression
  58
• 2 Valve gear
  61
• 2.1 Assembly overview - valve gear
  61
• 2.2 Checking valve guides
  64
• 2.3 Renewing valve stem oil seals
  65
• 2.4 Removing and installing camshaft
  66
• 2.5 Removing and installing camshaft oil seal
  70
• Lubrication
  73
• 1 Engine oil
  73
• 1.1 Oil capacities
  73
• 1.2 Checking engine oil level
  73
• 2 Parts of lubrication system
  74
• 2.1 Assembly overview - parts of lubrication system
  74
• 2.2 Removing and installing sump
  75
• 2.3 Assembly overview - oil filter bracket
  77
• 2.4 Checking oil pressure and oil pressure switch
  78
• 2.5 Assembly overview - oil supply line
  79
• 2.6 Removing and installing oil supply line
  80
• Cooling
  83
• 1 Parts of cooling system
  83
• 1.1 Assembly overview - parts of cooling system, body side
  84
• 1.2 Assembly overview - parts of cooling system, engine side
  87
• 1.3 Coolant hose schematic diagram
  88
• 1.4 Draining and filling coolant
  92
• 1.5 Removing and installing radiator
  94
• 1.6 Removing and installing coolant pump
  96
• 1.7 Removing and installing thermostat
  97
• 1.8 Checking cooling system for leaks
  99
• 1.9 Checking oil cooler for leaks
  101
• Fuel supply system
  104
• 1 Removing and installing parts of fuel supply system
  104
• 1.1 Safety precautions when working on fuel supply system
  104
• 1.2 Rules for cleanliness
  105
• 1.3 Assembly overview - fuel tank with attachments
  105
• 1.4 Assembly overview - fuel filter
  108
• 1.5 Removing and installing fuel cooler
  109
• 1.6 Removing and installing fuel tank
  110
• 1.7 Removing and installing fuel delivery unit
  111
• 1.8 Removing and installing fuel gauge sender G
  113
• 1.9 Checking fuel pump
  114
• 1.10 Assembly overview - accelerator mechanism
  115
• 1.11 Checking tandem pump
  116
• 1.12 Removing and installing tandem pump
  119
• Turbocharging/supercharging
  123
• 1 Charge air system with turbocharger
  123
• 1.1 Safety precautions
  123
• 1.2 Rules for cleanliness
  124
• 1.4 Hose connections with spring band ring
  125
• 1.5 Assembly overview - turbocharger with attachments
  125
• 1.6 Removing and installing turbocharger, engine code BMT
  130
• 1.7 Assembly overview - parts of charge air cooling
  132
• 1.8 Checking charge air system for leaks
  134
• Mixture preparation - injection
  137
• 1 Repairing diesel direct injection system
  137
• 1.1 Safety precautions
  137
• 1.2 Rules for cleanliness
  138
• 1.3 Assembly overview - intake manifold with intake manifold flap
  138
• 1.4 Assembly overview - air filter
  142
• 1.5 Assembly overview - unit injector
  142
• 1.6 Removing and installing unit injector O-rings
  143
• 1.7 Removing and installing unit injector
  145
• 2 Engine control unit
  149
• 2.1 Reading and clearing engine control unit fault memory
  149
• 2.2 Adapting functions and components
  149
• 2.3 Removing and installing engine control unit
  150
• Exhaust system
  155
• 1 Exhaust system
  155
• 1.1 Assembly overview - front exhaust pipe with catalytic converter and silencers
  157
• 1.2 Assembly overview - front exhaust pipe with particulate filter
  158
• 1.3 Assembly overview - silencer (vehicle with particulate filter)
  160
• 1.4 Removing and installing front exhaust pipe with particulate filter
  160
• 1.5 Aligning exhaust system stress free
  163
• 2 Exhaust gas recirculation system
  165
• 2.1 Assembly overview - parts of exhaust gas recirculation
  165
• 2.2 Assembly overview - exhaust gas recirculation cooler, engine code BMT
  169
• 2.3 Removing and installing exhaust gas recirculation cooler, engine code BMT
  170
• 2.4 Schematic diagram for vacuum hoses
  171
• Glow plug system
  172
• 1 Checking glow plug system
  172
• 1.1 Removing, installing and checking glow plugs
  172
• 1.2 Characteristics of ceramic glow plugs
  173
• 1.3 Removing, installing and checking ceramic glow plugs
  173