4-cylinder diesel engine (2.0 l engine)

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 Notes on removing
  4
• 1.2 Notes on installing
  7
• 1.3 Torque settings
  8
• 1.4 Front engine mounting
  8
• 1.5 Additional information and removal instructions for vehicles with air conditioner
  9
• Crankshaft group
  11
• 1 Dismantling and assembling engine
  11
• 1.1 Overview
  11
• 1.2 Removing and installing air conditioner compressor poly V-belt
  17
• 1.3 Removing and installing poly V-belt
  18
• 2 Removing and installing sealing flanges and flywheel or drive plate
  19
• 2.1 Assembly overview - sealing flange and flywheel/drive plate
  19
• 2.2 Renewing crankshaft oil seal - pulley end
  20
• 2.3 Removing and installing drive plate
  22
• 2.4 Removing and installing sealing flange - pulley end
  23
• 3 Removing and installing crankshaft
  27
• 3.1 Assembly overview - crankshaft
  27
• 3.2 Pulling needle roller bearing out of and driving into crankshaft
  29
• 3.3 Crankshaft dimensions
  30
• 4 Dismantling and assembling pistons and conrods
  31
• 4.1 Assembly overview - pistons and conrods
  31
• 4.2 Piston and cylinder
  32
• 4.3 Checking piston projection at TDC
  34
• 4.4 Piston and cylinder dimensions
  35
• Cylinder head, valve gear
  36
• 1 Cylinder head
  36
• 1.1 Assembly overview - cylinder head
  36
• 1.2 Removing, installing and tensioning toothed belts
  39
• 1.3 Removing and installing cylinder head
  43
• 1.4 Checking compression
  47
• 2 Repairing valve gear
  50
• 2.1 Assembly overview - valve gear
  50
• 2.2 Checking valve guides
  52
• 2.3 Renewing valve stem seals
  53
• 2.4 Removing and installing camshaft
  54
• 2.5 Removing and installing camshaft oil seal
  58
• Lubrication
  60
• 1 Parts of lubrication system
  60
• 1.1 Engine oil
  60
• 1.2 Part I
  60
• 1.3 Part II
  62
• 1.4 Part III
  65
• 1.5 Removing and installing oil pump
  66
• 1.6 Removing and installing balancer shaft module
  68
• 1.7 Converting balancer shaft module to spur gear drive
  70
• 1.8 Assembly overview - oil supply line
  76
• 1.9 Removing and installing sump
  77
• 1.10 Checking oil pressure and oil pressure switch
  82
• Cooling
  85
• 1 Removing and installing parts of cooling system
  85
• 1.1 Parts of cooling system - body side
  85
• 1.2 Parts of cooling system - engine side
  87
• 1.3 Draining and filling coolant
  89
• 1.4 Removing and installing radiator
  92
• 1.5 Removing and installing coolant pump
  94
• 1.6 Removing and installing thermostat
  96
• 1.7 Removing and installing viscous fan coupling
  98
• Fuel supply system
  100
• 1 Parts of fuel system
  100
• 1.1 Safety precautions when working on fuel supply system
  100
• 1.2 Rules for cleanliness
  101
• 1.3 Assembly overview - fuel tank
  101
• 1.4 Assembly overview - fuel filter
  104
• 1.5 Removing and installing fuel cooler
  105
• 1.6 Emptying fuel tank
  106
• 1.7 Removing and installing fuel tank
  106
• 1.8 Checking fuel pump
  109
• 1.9 Removing and installing fuel delivery unit
  113
• 1.10 Removing and installing fuel gauge sender
  118
• 1.11 Assembly overview - accelerator mechanism
  118
• 1.12 Checking tandem pump
  119
• 1.13 Removing and installing tandem pump
  121
• 2 Additive container
  124
• 2.1 Safety precautions when working on additive container
  124
• 2.2 Removing and installing additive container
  124
• 2.3 Assembly overview - additive container
  125
• Turbocharging/supercharging
  128
• 1 Charge air system with turbocharger
  128
• 1.1 Safety precautions
  128
• 1.2 Rules for cleanliness
  128
• 1.3 Hose connections with push-on connectors
  129
• 1.4 Assembly overview - turbocharger
  129
• 1.5 Assembly overview - charge air cooling
  131
• Mixture preparation - injection
  133
• 1 Repairing diesel direct injection system
  133
• 1.1 Safety precautions
  133
• 1.2 Rules for cleanliness
  134
• 1.3 Assembly overview - intake manifold with intake manifold flap motor
  134
• 1.4 Assembly overview - air filter
  136
• 1.5 Assembly overview - unit injector
  136
• 1.6 Removing and installing unit injector O-rings
  137
• 1.7 Removing and installing unit injector
  139
• 2 Engine control unit
  143
• 2.1 Reading and erasing engine control unit fault memory
  143
• 2.2 Adapting functions and components
  144
• 2.3 Removing and installing engine control unit
  145
• Exhaust system
  146
• 1 Removing and installing parts of exhaust system
  146
• 1.3 Assembly overview - silencer with mountings
  149
• 2 Exhaust gas recirculation system
  151
• 2.1 Assembly overview - exhaust gas recirculation
  151
• Glow plug system
  153
• 1 Checking glow plug system
  153
• 1.1 Removing, installing and checking ceramic glow plugs
  153