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

Chapter overview

• Technical data
  1
• 1 Identification
  1
• 1.1 Engine number/engine data
  1
• 2 Safety information
  2
• 2.1 Safety precautions when working on injection system
  2
• 2.2 Safety precautions when working on charge air system
  3
• 2.3 Safety measures when working on fuel supply
  3
• 2.4 Safety precautions when working on the cooling system
  4
• 3 Repair instructions
  5
• 3.1 Rules for cleanliness during work on fuel system
  5
• 3.2 Rules for cleanliness when working on fuel supply system/injection system
  5
• 3.3 General notes on the lubrication system
  5
• Removing and installing engine
  7
• 1 Removing and installing engine
  7
• 1.1 Removing engine
  7
• 1.2 Securing engine on engine and gearbox support
  12
• 1.3 Installing engine
  14
• 2 Assembly mountings
  16
• 2.1 Assembly overview - assembly mountings
  16
• Crankshaft group
  18
• 1 Cylinder block (pulley end)
  18
• 1.1 Assembly overview - poly V-belt drive
  18
• 1.2 Assembly overview - cylinder block
  19
• 1.3 Removing and installing poly-V belt
  20
• 1.4 Renewing crankshaft oil seal - belt pulley end
  22
• 1.5 Removing and installing sealing flange on pulley end
  24
• 2 Cylinder block, gearbox end
  28
• 2.1 Assembly overview - cylinder block, gearbox end
  28
• 2.2 Removing and installing sealing flange on gearbox side
  29
• 3 Crankshaft
  38
• 3.1 Assembly overview - crankshaft
  38
• 3.2 Crankshaft dimensions
  38
• 3.3 Renewing needle bearing in crankshaft
  39
• 4 Pistons and conrods
  41
• 4.1 Assembly overview - pistons and conrods
  41
• 4.2 Measuring piston projection at TDC
  42
• 4.3 Piston and cylinder dimensions
  43
• 4.4 Checking pistons and cylinder bores
  43
• Cylinder head, valve gear
  46
• 1 Cylinder head
  46
• 1.1 Assembly overview - cylinder head
  46
• 1.2 Removing and installing cylinder head
  49
• 1.3 Removing and installing cylinder head cover
  56
• 1.4 Checking compression
  58
• 2 Toothed belt drive
  60
• 2.1 Assembly overview - toothed belt drive
  60
• 2.2 Removing and installing toothed belt
  62
• 2.3 Loosening and securing toothed belt
  69
• 3 Valve gear
  75
• 3.1 Assembly overview - valve gear
  75
• 3.2 Measuring axial play of camshaft
  77
• 3.3 Removing and installing camshaft oil seal
  77
• 3.4 Removing and installing camshaft
  79
• 3.5 Removing and installing valve stem seals
  83
• 4 Inlet and exhaust valves
  86
• 4.1 Checking valve guides
  86
• 4.2 Valve dimensions
  86
• Lubrication
  87
• 1 Sump, oil pump
  87
• 1.1 Assembly overview - sump/oil pump
  87
• 1.2 Removing and installing sump
  89
• 1.3 Engine oil:
  91
• 2 Oil filter, oil pressure switch
  92
• 2.1 Assembly overview - oil filter housing with engine oil cooler
  92
• 2.2 Checking oil pressure and oil pressure switch
  93
• 2.3 Measuring oil consumption
  94
• Cooling
  95
• 1 Cooling system/coolant
  95
• 1.1 Connection diagram - coolant hoses
  95
• 1.2 Draining and adding coolant
  96
• 1.3 Checking cooling system for leaks
  103
• 1.4 Checking engine oil cooler for leaks
  104
• 2 Coolant pump, regulation of cooling system
  107
• 2.1 Assembly overview - coolant pump, thermostat
  107
• 2.2 Removing and installing coolant pump
  109
• 2.3 Removing and installing thermostat
  110
• 3 Radiator, radiator fan
  113
• 3.1 Assembly overview - radiator/radiator fan
  113
• 3.2 Removing and installing radiator
  115
• 3.3 Removing and installing fan mounting with fans
  116
• Turbocharging/supercharging
  119
• 1 Turbocharger
  119
• 1.1 Assembly overview - turbocharger
  119
• 1.2 Removing and installing turbocharger
  121
• 2 Charge air system
  125
• 2.1 Assembly overview - charge air system
  125
• 2.2 Assembly overview - charge-air hose connections
  126
• 2.3 Checking charge air system for leaks
  126
• Mixture preparation - injection
  129
• 1 Injectors
  129
• 1.1 Assembly overview - injectors
  129
• 1.2 Assembly overview - prewiring for unit injectors
  130
• 1.3 Removing and installing O-rings for unit injector
  130
• 1.4 Removing and installing unit injector
  131
• 1.5 Removing and installing prewiring for unit injectors
  134
• 2 Vacuum system
  138
• 2.1 Connection diagram - vacuum system
  138
• 3 Air filter
  139
• 3.1 Assembly overview - air filter housing
  139
• 4 Intake manifold
  140
• 4.1 Assembly overview - intake manifold
  140
• 4.2 Cleaning intake manifold flap connection
  141
• 5 Engine control unit
  142
• 5.1 Removing and installing engine control unit
  142
• 6 High-pressure pump
  144
• 6.1 Removing and installing tandem pump
  144
• 6.2 Checking delivery pressure of tandem pump
  146
• 6.3 Checking for internal leaks
  148
• Exhaust system
  150
• 1 Exhaust pipes and silencers
  150
• 1.1 Assembly overview - silencers
  150
• 1.2 Separating exhaust pipes from silencers
  151
• 1.3 Installation position of clamp
  152
• 1.4 Aligning exhaust system free of stress
  152
• 2 Emission control
  153
• 2.1 Assembly overview - emission control
  153
• 2.2 Removing and installing particulate filter
  154
• 3 Exhaust gas temperature regulation
  158
• 3.1 Assembly overview - exhaust gas temperature regulation
  158
• 4 Exhaust gas recirculation
  159
• 4.1 Assembly overview - exhaust gas recirculation
  159
• 4.2 Assembly overview - exhaust gas recirculation cooler
  160
• Glow plug system
  162
• 1 Glow plug system
  162
• 1.1 Handling ceramic glow plugs
  162
• 1.2 Removing and installing ceramic glow plugs
  162
• 1.3 Removing and installing engine speed sender G28
  164