4-cylinder unit injector diesel engine

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 Fastening the engine to the assembly stand
  8
• 1.3 Notes on installation
  9
• 1.4 Torque settings
  12
• 1.5 Aligning engine and gearbox mountings
  12
• 1.6 Assembly mountings
  13
• Crankshaft group
  16
• 1 Dismantling and assembling engine
  16
• 1.1 Assembly overview
  16
• 1.2 Removing and installing poly V-belt
  21
• 2 Sealing flanges and flywheel
  24
• 2.1 Assembly overview
  24
• 2.2 Renewing crankshaft oil seal - belt pulley end
  25
• 2.3 Removing and installing sealing flange -belt pulley end-
  26
• 3 Crankshaft
  29
• 3.1 Assembly overview
  29
• 3.3 Crankshaft dimensions
  32
• 4 Piston and conrod
  33
• 4.1 Assembly overview
  33
• 4.2 Checking piston projection at TDC
  36
• 4.3 Piston and cylinder dimensions
  37
• Cylinder head, valve gear
  38
• 1 Cylinder head
  38
• 1.1 Assembly overview
  38
• 1.2 Removing and installing cylinder head cover
  41
• 1.3 Removing and installing toothed belt
  43
• 1.4 Removing and installing cylinder head
  55
• 1.5 Check compression pressures
  63
• 2 Valve gear
  66
• 2.1 Assembly overview
  66
• 2.2 Removing and installing camshaft oil seal
  69
• 2.3 Removing and installing camshaft
  70
• 2.4 Renewing valve stem seals
  74
• 2.5 Checking valve guides
  76
• Lubrication
  78
• 1 Parts of the lubrication system
  78
• 1.1 Engine oil
  78
• 1.2 Assembly overview
  79
• 1.3 Removing and installing oil pan
  87
• 1.4 Removing and installing oil pump
  89
• 1.5 Checking oil pressure and oil pressure switch
  90
• Cooling system
  93
• 1 Parts of cooling system
  93
• 1.1 Parts of cooling system - body side - Assembly overview
  93
• 1.2 Parts of cooling system - engine side - Assembly overview
  95
• 1.3 Coolant hose schematic diagram
  100
• 1.4 Draining and filling coolant
  104
• 1.5 Removing and installing radiator
  107
• 1.6 Removing and installing coolant pump
  109
• 1.7 Removing and installing thermostat
  111
• 1.8 Checking glow pin plugs
  112
• Fuel supply system
  114
• 1 Parts of fuel supply system
  114
• 1.1 Safety precautions when working on fuel supply system
  115
• 1.2 Rules for cleanliness
  115
• 1.3 Fuel tank with attachments - Assembly overview
  116
• 1.4 Fuel fliter - Assembly overview
  118
• 1.5 Fuel cooler - Assembly overview
  119
• 1.6 Emptying fuel tank
  119
• 1.7 Removing and installing fuel delivery unit
  122
• 1.8 Removing and installing fuel gauge sender
  123
• 1.9 Check fuel gauge sender
  124
• 1.10 Removing and installing fuel tank
  125
• 1.11 Checking fuel pump
  127
• 1.12 Check tandem pump
  132
• 1.13 Removing and installing tandem pump
  134
• 2 Electronic power control (EPC)
  137
• 2.1 Function of EPC system
  137
• 2.2 Accelerator pedal module - Assembly overview
  137
• Charging
  139
• 1 Charge air system with turbocharger
  139
• 1.1 Safety precautions
  140
• 1.2 Rules for cleanliness
  140
• 1.3 Turbocharger with attachments - Assembly overview
  140
• 1.4 Parts of charge air cooling - Assembly overview
  146
• 1.5 Vacuum hoses for connection diagram
  148
• 1.6 Removing and installing charge air cooler
  152
• Mixture preparation, Injection
  154
• 1 Diesel direct injection system
  154
• 1.1 Safety precautions
  154
• 1.2 Rules for cleanliness
  155
• 1.3 Fitting locations overview
  155
• 1.4 Intake manifold flap - Assembly overview
  158
• 1.5 Servicing unit injector - Assembly overview
  163
• 1.6 Installing and removing unit injector
  164
• 1.7 Removing and installing O-rings for injector unit
  168
• 1.8 Air filter - Assembly overview
  169
• 2 Engine control unit
  171
• 2.1 Reading and erasing engine control unit fault memory
  171
• 2.2 Removing and installing engine control unit
  172
• Exhaust system
  174
• 1 Parts of exhaust system
  174
• 1.1 Front exhaust pipe and catalyst with attachments - Assembly overview
  174
• 1.2 Silencer with mountings - Assembly overview
  177
• 2 Exhaust gas recirculation system
  179
• 2.1 Parts of exhaust gas recirculation - Assembly overview
  179
• 2.2 Check exhaust gas recirculation valve - engine codes ATD, AXR, BSW
  183
• Glow plug system
  187
• 1 Glow plug system
  187
• 1.1 Removing and installing glow plugs, checking
  187