4-cylinder diesel engine (2.0 l engine, 2-valve, SDI)

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
  8
• 1.3 Notes on installing
  8
• 1.4 Assembly mountings
  9
• Crankshaft group
  11
• 1 Dismantling and assembling engine
  11
• 1.1 Assembly overview - toothed belt drive
  11
• 1.2 Assembly overview - poly V-belt drive
  13
• 1.3 Removing and installing poly V-belt
  13
• 1.4 Assembly overview - crankcase
  15
• 2 Removing and installing sealing flange and flywheel
  17
• 2.1 Assembly overview - sealing flange and flywheel
  17
• 2.2 Renewing crankshaft oil seal - pulley end
  18
• 2.3 Removing and installing sealing flange - pulley end
  20
• 2.4 Renewing crankshaft sealing flange - flywheel end
  22
• 3 Crankshaft
  31
• 3.1 Assembly overview - crankshaft
  31
• 3.2 Crankshaft dimensions
  32
• 4 Pistons and conrods
  33
• 4.1 Assembly overview - pistons and conrods
  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 - cylinder head
  38
• 1.2 Removing and installing cylinder head cover
  41
• 1.3 Removing, installing and tensioning toothed belts
  43
• 1.4 Removing and installing cylinder head
  57
• 1.5 Checking compression
  61
• 2 Repairing valve gear
  64
• 2.1 Assembly overview - valve gear
  64
• 2.2 Checking valve guides
  66
• 2.3 Renewing valve stem seals
  67
• 2.4 Removing and installing camshaft
  69
• 2.5 Removing and installing camshaft oil seal
  73
• Lubrication
  76
• 1 Engine oil
  76
• 1.1 Oil capacities
  76
• 1.2 Engine oil specifications
  76
• 1.3 Checking engine oil level
  76
• 2 Parts of lubrication system
  77
• 2.1 Assembly overview - oil pump, oil sump
  77
• 2.2 Removing and installing oil sump
  78
• 3 Oil filter bracket, oil cooler and oil pressure
  82
• 3.1 Assembly overview - oil filter bracket and oil cooler
  82
• 3.2 Checking oil pressure and oil pressure switch
  83
• Cooling
  85
• 1 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 Coolant hose schematic diagram
  89
• 1.4 Draining and filling coolant
  90
• 1.5 Removing and installing fan support with fans
  92
• 1.6 Removing and installing radiator
  93
• 1.7 Removing and installing coolant pump
  95
• 1.8 Removing and installing thermostat
  97
• 1.9 Checking cooling system for leaks
  99
• 1.10 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
  105
• 1.4 Assembly overview - fuel filter
  108
• 1.5 Removing and installing fuel cooler
  109
• 1.6 Emptying fuel tank
  109
• 1.7 Removing and installing fuel tank
  112
• 1.8 Removing and installing fuel delivery unit
  114
• 1.9 Removing and installing fuel sender
  115
• 1.10 Checking fuel pump
  116
• 1.11 Checking tandem pump
  117
• 1.12 Removing and installing tandem pump
  121
• 1.13 Assembly overview - accelerator mechanism
  124
• Mixture preparation - injection
  126
• 1 Repairing diesel direct injection system
  126
• 1.1 Safety precautions
  126
• 1.2 Rules for cleanliness
  127
• 1.3 Assembly overview - unit injector
  127
• 1.4 Removing and installing O-rings for unit injector
  128
• 1.5 Removing and installing unit injector
  130
• 1.6 Assembly overview - intake manifold with intake manifold flap
  132
• 1.7 Assembly overview - air filter
  134
• 2 Engine control unit
  135
• 2.1 Reading and erasing engine control unit fault memory
  135
• 2.2 Adapting functions and components
  136
• 2.3 Removing and installing anti-theft engine control unit
  137
• Exhaust system
  140
• 1 Removing and installing parts of exhaust system
  140
• 1.2 Assembly overview - silencer with mountings
  142
• 2 Exhaust gas recirculation system
  145
• 2.1 Assembly overview - parts of exhaust gas recirculation
  145
• 2.2 Vacuum hose schematic diagram
  146
• 2.3 Checking exhaust gas recirculation valve (mechanical)
  147
• Glow plug system
  148
• 1 Checking glow plug system
  148
• 1.1 Checking glow plugs
  148