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
  7
• 1.3 Notes on installing
  8
• 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 flange and flywheel
  19
• 2.2 Renewing crankshaft oil seal - pulley end
  20
• 2.3 Removing and installing sealing flange - pulley end
  22
• 2.4 Renewing crankshaft sealing flange - flywheel end
  24
• 3 Crankshaft
  33
• 3.1 Assembly overview - crankshaft
  33
• 3.2 Crankshaft dimensions
  34
• 3.3 Pulling needle bearing out of and driving into crankshaft
  34
• 4 Pistons and conrods
  36
• 4.1 Assembly overview - pistons and conrods
  36
• 4.2 Separating new conrods
  37
• 4.3 Checking piston projection at TDC
  38
• 4.4 Piston and cylinder dimensions
  39
• 4.5 Piston rings, cylinder bore and piston installation position
  39
• Cylinder head, valve gear
  42
• 1 Cylinder head
  42
• 1.1 Assembly overview - cylinder head
  42
• 1.2 Removing and installing cylinder head cover
  45
• 1.3 Removing, installing and tensioning toothed belts
  47
• 1.4 Removing and installing cylinder head
  61
• 1.5 Checking compression
  65
• 2 Repairing valve gear
  68
• 2.1 Assembly overview - valve gear
  68
• 2.2 Checking valve guides
  70
• 2.3 Renewing valve stem seals
  71
• 2.4 Removing and installing camshaft
  73
• 2.5 Removing and installing camshaft oil seal
  77
• Lubrication
  80
• 1 Engine oil
  80
• 1.1 Oil capacities
  80
• 1.2 Checking engine oil level
  80
• 2 Parts of lubrication system
  81
• 2.1 Assembly overview - oil pump, sump
  81
• 2.2 Removing and installing sump
  82
• 3 Oil filter bracket, oil pressure and oil cooler
  85
• 3.1 Assembly overview - oil filter bracket and oil cooler
  85
• 3.2 Checking oil pressure and oil pressure switch
  86
• Cooling
  88
• 1 Parts of cooling system
  88
• 1.1 Parts of cooling system, body side
  88
• 1.2 Parts of cooling system - engine side
  90
• 1.3 Coolant hose schematic diagram
  92
• 1.4 Draining and filling coolant
  93
• 1.5 Removing and installing fan support with fans
  96
• 1.6 Removing and installing radiator
  97
• 1.7 Removing and installing coolant pump
  99
• 1.8 Removing and installing thermostat
  101
• 1.9 Checking cooling system for leaks
  102
• 1.10 Checking oil cooler for leaks
  104
• Fuel supply system
  107
• 1 Removing and installing parts of fuel supply system
  107
• 1.1 Safety precautions when working on fuel supply system
  107
• 1.2 Rules for cleanliness
  108
• 1.3 Assembly overview - fuel tank
  108
• 1.4 Assembly overview - fuel filter
  110
• 1.5 Removing and installing fuel cooler
  111
• 1.6 Emptying fuel tank
  112
• 1.7 Removing and installing fuel tank
  114
• 1.8 Removing and installing fuel delivery unit
  116
• 1.9 Removing and installing fuel gauge sender
  118
• 1.10 Checking fuel pump
  119
• 1.11 Checking tandem pump
  120
• 1.12 Removing and installing tandem pump
  124
• 1.13 Assembly overview - accelerator mechanism
  127
• Turbocharging/supercharging
  129
• 1 Charge air system with turbocharger
  129
• 1.1 Safety precautions
  129
• 1.2 Rules for cleanliness
  129
• 1.3 Installing hose connections with connector couplings
  130
• 1.4 Assembly overview - turbocharger
  131
• 1.5 Assembly overview - charge air cooling
  132
• 1.6 Checking charge air system for leaks
  133
• 1.7 Vacuum hose schematic diagram
  135
• Mixture preparation - injection
  137
• 1 Repairing diesel direct injection system
  137
• 1.1 Safety precautions
  137
• 1.2 Rules for cleanliness
  138
• 1.3 Assembly overview - unit injector
  138
• 1.4 Removing and installing O-rings for unit injector
  139
• 1.5 Removing and installing unit injector
  140
• 1.6 Assembly overview - intake manifold with intake manifold flap
  143
• 1.7 Assembly overview - air filter
  145
• 2 Engine control unit
  146
• 2.1 Reading and clearing engine control unit fault memory
  146
• 2.2 Adapting functions and components
  147
• 2.3 Removing and installing engine control unit
  147
• 2.4 Removing and installing anti-theft engine control unit
  148
• Exhaust system
  151
• 1 Parts of the exhaust system
  151
• 1.1 Assembly overview - front exhaust pipe with particulate filter
  151
• 1.2 Assembly overview - silencer with mountings
  153
• 2 Exhaust gas recirculation system
  156
• 2.1 Assembly overview - exhaust gas recirculation
  156
• 2.2 Assembly overview - exhaust gas recirculation cooler
  157
• Glow plug system
  158
• 1 Checking glow plug system
  158
• 1.1 Characteristics of ceramic glow plugs
  158
• 1.2 Removing, installing and checking ceramic glow plugs
  158