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

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 Installing engine
  9
• 1.4 Assembly mountings
  11
• Crankshaft group
  12
• 1 Dismantling and assembling engine
  12
• 1.1 Assembly overview - toothed belt drive
  12
• 1.2 Assembly overview - poly V-belt drive
  14
• 1.3 Removing and installing poly V-belt
  14
• 1.4 Assembly overview - crankcase
  16
• 2 Removing and installing sealing flange and flywheel
  19
• 2.1 Assembly overview - sealing flanges and flywheel
  19
• 2.2 Renewing crankshaft oil seal - pulley end
  21
• 2.3 Removing and installing sealing flange - pulley end
  22
• 2.4 Renewing crankshaft sealing flange - flywheel end
  25
• 2.5 Removing and installing dual-mass flywheel
  32
• 2.6 Removing and installing engine speed sender G28
  34
• 3 Crankshaft
  36
• 3.1 Assembly overview - crankshaft
  36
• 3.2 Crankshaft dimensions
  37
• 3.3 Pulling needle bearing out of and driving into crankshaft
  37
• 4 Pistons and conrods
  39
• 4.1 Assembly overview - pistons and conrods
  39
• 4.2 Separating new conrod
  40
• 4.3 Checking piston projection at TDC
  41
• 4.4 Piston and cylinder dimensions
  42
• 4.5 Piston rings, cylinder bore and piston installation position
  42
• Cylinder head, valve gear
  45
• 1 Cylinder head
  45
• 1.1 Assembly overview - cylinder head
  45
• 1.2 Removing and installing cylinder head cover
  48
• 1.3 Removing, installing and tensioning toothed belt
  50
• 1.4 Removing and installing cylinder head
  65
• 1.5 Checking compression
  69
• 2 Repairing valve gear
  72
• 2.1 Assembly overview - valve gear
  72
• 2.2 Checking valve guides
  74
• 2.3 Renewing valve stem seals
  75
• 2.4 Removing and installing camshaft
  77
• 2.5 Removing and installing camshaft oil seal
  81
• Lubrication
  84
• 1 Engine oil
  84
• 1.1 Oil capacities
  84
• 1.2 Checking engine oil level
  84
• 2 Parts of lubrication system
  85
• 2.1 Assembly overview - oil pump, sump
  85
• 2.2 Removing and installing oil sump
  86
• 3 Oil filter bracket, oil pressure and oil cooler
  89
• 3.1 Assembly overview - oil filter bracket and oil cooler
  89
• 3.2 Checking oil pressure and oil pressure switch
  90
• Cooling
  92
• 1 Parts of cooling system
  92
• 1.1 Parts of cooling system, body side
  92
• 1.2 Parts of cooling system, engine side
  94
• 1.3 Coolant hose schematic diagram
  96
• 1.4 Draining and filling coolant
  96
• 1.5 Removing and installing fan support with fans
  100
• 1.6 Removing and installing radiator
  101
• 1.7 Removing and installing coolant pump
  103
• 1.8 Removing and installing thermostat
  105
• 1.9 Checking cooling system for leaks
  106
• 1.10 Checking oil cooler for leaks
  108
• Fuel supply system
  111
• 1 Removing and installing parts of fuel supply system
  111
• 1.1 Safety precautions when working on fuel supply system
  111
• 1.2 Rules for cleanliness
  112
• 1.3 Assembly overview - fuel tank
  112
• 1.4 Assembly overview - fuel filter
  115
• 1.5 Removing and installing fuel cooler
  116
• 1.6 Emptying fuel tank
  117
• 1.7 Removing and installing fuel tank
  120
• 1.8 Removing and installing fuel delivery unit
  122
• 1.9 Removing and installing fuel gauge sender
  125
• 1.10 Checking fuel pump
  125
• 1.11 Checking tandem pump
  127
• 1.12 Removing and installing tandem pump
  132
• 1.13 Assembly overview - accelerator mechanism
  135
• Turbocharging/supercharging
  138
• 1 Charge air system with turbocharger
  138
• 1.1 General notes
  138
• 1.2 Safety precautions
  139
• 1.3 Rules for cleanliness
  139
• 1.4 Hose connections
  140
• 1.5 Assembly overview - turbocharger
  141
• 1.6 Removing and installing turbocharger
  143
• 1.7 Assembly overview - charge air cooling
  144
• 1.8 Removing and installing charge air cooler
  146
• 1.9 Checking charge air system for leaks
  147
• Mixture preparation - injection
  150
• 1 Repairing diesel direct injection system
  150
• 1.1 Safety precautions
  151
• 1.2 Rules for cleanliness
  152
• 1.3 Assembly overview - unit injector
  152
• 1.4 Removing and installing unit injector
  154
• 1.5 Removing and installing O-rings for unit injector
  157
• 1.6 Assembly overview - intake manifold with intake manifold flap motor
  158
• 1.7 Assembly overview - air filter
  160
• 2 Engine control unit
  161
• 2.1 Reading and erasing engine control unit fault memory
  161
• 2.2 Adapting functions and components
  162
• 2.3 Removing and installing engine control unit
  163
• Exhaust system
  168
• 1 Exhaust system
  168
• 1.1 Assembly overview - front exhaust pipe with particulate filter
  170
• 1.2 Assembly overview - silencers with mountings
  172
• 1.3 Separating and joining front and rear silencers
  172
• 1.4 Aligning exhaust system free of stress
  174
• 2 Exhaust gas recirculation system
  176
• 2.1 Assembly overview - exhaust gas recirculation
  176
• 2.2 Assembly overview - exhaust gas recirculation cooler
  177
• Glow plug system
  178
• 1 Checking glow plug system
  178
• 1.1 Characteristics of ceramic glow plugs
  178
• 1.2 Removing, installing and checking ceramic glow pin plugs
  178