4-cylinder injection engine (natural gas)

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety precautions when working on vehicles with a gas system
  1
• 1.2 Safety regulations for working on fuel supply
  3
• 1.3 Safety measures when working on vehicles with a start/stop system
  3
• 1.5 Safety precautions when working on exhaust system
  4
• 2 Identification
  5
• 2.1 Engine number/engine data
  5
• 3 Repair instructions
  6
• 3.1 General information
  6
• Removing and installing engine
  8
• 1 Removing and installing engine
  8
• 1.1 Removing engine
  8
• 1.2 Securing engine on engine and gearbox support
  12
• 1.3 Installing engine
  14
• 2 Assembly mountings
  17
• 2.1 Assembly overview - assembly mountings
  17
• Crankshaft group
  18
• 1 Cylinder block (pulley end)
  18
• 1.1 Assembly overview - poly V-belt drive
  18
• 1.2 Assembly overview - cylinder block (pulley end)
  20
• 1.3 Removing and installing poly-V belt
  21
• 1.4 Renewing crankshaft oil seal - belt pulley end
  22
• 1.5 Removing and installing sealing flange on pulley end
  25
• 2 Cylinder block, gearbox end
  29
• 2.1 Assembly overview - cylinder block, gearbox end
  29
• 2.2 Removing and installing sealing flange on gearbox side
  30
• 3 Crankshaft
  32
• 3.1 Assembly overview - crankshaft
  32
• 3.2 Allocation of main bearing shells
  33
• 3.3 Removing and installing sender wheel
  34
• 3.4 Crankshaft dimensions
  34
• 4 Pistons and conrods
  35
• 4.1 Assembly overview - pistons and conrods
  35
• 4.2 Checking pistons and cylinder bores
  36
• Cylinder head, valve gear
  39
• 1 Cylinder head
  39
• 1.1 Assembly overview - cylinder head
  39
• 1.2 Removing and installing cylinder head
  41
• 1.3 Checking compression
  46
• 2 Toothed belt drive
  49
• 2.1 Assembly overview - toothed belt
  49
• 2.2 Removing and installing toothed belt
  51
• 3 Valve gear
  57
• 3.1 Assembly overview - valve gear
  57
• 3.2 Measuring axial play of camshaft
  59
• 3.3 Removing and installing camshaft oil seal
  59
• 3.4 Removing and installing camshaft
  61
• 3.5 Removing and installing valve stem seals
  64
• 4 Inlet and exhaust valves
  67
• 4.1 Reworking valve seats
  67
• 4.2 Checking valve guides
  69
• 4.3 Valve dimensions
  70
• Lubrication
  71
• 1 Sump, oil pump
  71
• 1.1 Assembly overview - sump/oil pump
  71
• 1.2 Removing and installing oil sump
  73
• 1.3 Removing and installing oil pump
  75
• 1.4 Engine oil:
  76
• 2 Oil filter, oil pressure switch
  77
• 2.1 Assembly overview - oil filter/oil pressure switch
  77
• 2.2 Checking oil pressure and oil pressure switch
  78
• Cooling
  80
• 1 Cooling system/coolant
  80
• 1.1 Connection diagram - coolant hoses
  80
• 1.2 Checking cooling system for leaks
  80
• 1.3 Draining and adding coolant
  82
• 2 Coolant pump, regulation of cooling system
  91
• 2.1 Assembly overview - coolant pump, thermostat
  91
• 2.2 Removing and installing coolant pump
  92
• 2.3 Removing and installing thermostat
  94
• 3 Radiator, radiator fan
  96
• 3.1 Assembly overview - radiator/radiator fan
  96
• 3.2 Removing and installing radiator
  97
• 3.3 Removing and installing radiator fan
  98
• Mixture preparation - injection
  101
• 1 Injection system
  101
• 1.1 Filling/bleeding fuel system
  101
• 2 Injectors
  104
• 2.1 Assembly overview - fuel rail with injectors
  104
• 2.2 Removing and installing injectors
  105
• 2.3 Checking injectors
  106
• 3 Checking natural gas supply system for leaks
  110
• 3.1 Distinguishing between pressure sections of natural gas supply system
  110
• 3.2 Determining pressure of natural gas system
  112
• 3.3 Determining operating mode of natural gas vehicles
  113
• 3.4 Activating and deactivating natural gas mode
  113
• 3.5 Checking gas system for leaks
  114
• 4 Gas injectors
  119
• 4.1 Assembly overview - gas rail with gas injectors
  119
• 5 Gas pressure regulator
  122
• 5.1 Assembly overview - gas pressure regulator
  122
• 5.2 Removing and installing gas pressure regulator
  124
• 6 Air filter
  131
• 6.1 Assembly overview - air filter housing
  131
• 7 Intake manifold
  132
• 7.1 Assembly overview - intake manifold
  132
• 7.2 Assembly overview - lower part of intake manifold with fuel rail
  133
• 7.3 Removing and installing intake manifold upper part
  133
• 8 Engine (motor) control unit
  136
• 8.1 Removing and installing engine (motor) control unit J623
  136
• Exhaust system
  139
• 1 Exhaust pipes and silencers
  139
• 1.1 Assembly overview - silencers
  139
• 1.2 Aligning exhaust system free of stress
  140
• 1.3 Check exhaust system for leaks
  141
• 1.4 Installation position of clamp
  141
• 2 Exhaust gas cleaning
  142
• 2.1 Assembly overview - emission control
  142
• 2.2 Removing and installing catalytic converter
  145
• Ignition system
  149
• 1 Ignition system
  149
• 1.1 Assembly overview - ignition system
  149
• 1.2 Test data, spark plugs
  150