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

Chapter overview

• Technical data
  1
• 1 Identification
  1
• 1.1 Engine number/engine data
  1
• 2 Safety information
  2
• 2.1 Safety measures when working on fuel supply
  2
• 2.2 Safety precautions when working on injection system
  3
• 2.4 Safety precautions when working on the cooling system
  4
• 3 Repair instructions
  5
• 3.1 Rules for cleanliness when working on fuel supply system
  5
• 3.2 Foreign objects in engine
  5
• 3.3 General notes on cooling system
  5
• 3.4 General notes on fuel supply system
  6
• Removing and installing engine
  8
• 1 Removing and installing engine
  8
• 1.1 Removing engine
  8
• 1.2 Securing engine on engine and gearbox support
  13
• 1.3 Installing engine
  15
• 2 Assembly mountings
  18
• 2.1 Assembly overview - assembly mountings
  18
• Crankshaft group
  20
• 1 Cylinder block (pulley end)
  20
• 1.1 Assembly overview - poly V-belt drive, vehicles with air conditioning system
  20
• 1.3 Assembly overview - cylinder block
  22
• 1.4 Removing and installing poly-V belt
  23
• 1.5 Renewing crankshaft oil seal - belt pulley end
  24
• 1.6 Removing and installing sealing flange on pulley end
  26
• 2 Cylinder block, gearbox end
  30
• 2.1 Assembly overview - cylinder block, gearbox end
  30
• 2.2 Renewing crankshaft sealing flange - flywheel end
  31
• 3 Crankshaft
  40
• 3.1 Assembly overview - crankshaft
  40
• 3.2 Crankshaft dimensions
  40
• 4 Pistons and conrods
  42
• 4.1 Assembly overview - pistons and conrods
  42
• 4.2 Checking pistons and cylinder bores
  44
• 4.3 Measuring piston projection at TDC
  45
• 4.4 Piston and cylinder dimensions
  46
• Cylinder head, valve gear
  47
• 1 Cylinder head
  47
• 1.1 Assembly overview - cylinder head
  47
• 1.2 Removing and installing cylinder head
  50
• 1.3 Removing and installing cylinder head cover
  56
• 1.4 Cylinder head gasket identification
  58
• 1.5 Checking compression
  58
• 2 Toothed belt drive
  60
• 2.1 Assembly overview - toothed belt
  60
• 2.2 Removing and installing toothed belt
  61
• 3 Valve gear
  77
• 3.1 Assembly overview - valve gear
  77
• 3.2 Measuring axial play of camshaft
  79
• 3.3 Removing and installing camshaft oil seal
  79
• 3.4 Removing and installing camshaft
  81
• 3.5 Renewing valve stem seals
  86
• 4 Inlet and exhaust valves
  89
• 4.1 Checking valve guides
  89
• Lubrication
  90
• 1 Sump, oil pump
  90
• 1.1 Assembly overview - sump/oil pump
  90
• 1.2 Removing and installing sump
  91
• 1.3 Engine oil:
  94
• 2 Oil filter, oil pressure switch
  95
• 2.1 Assembly overview - oil filter housing, oil pressure switch
  95
• 2.2 Checking oil pressure and oil pressure switch
  96
• 2.3 Measuring oil consumption
  97
• Cooling
  98
• 1 Cooling system/coolant
  98
• 1.1 Coolant hose schematic diagram, engine code BDJ
  98
• 1.2 Checking cooling system for leaks
  100
• 1.3 Draining and adding coolant
  101
• 1.4 Checking engine oil cooler for leaks
  110
• 2 Coolant pump, regulation of cooling system
  112
• 2.1 Assembly overview - coolant pump and thermostat, engine code BDJ
  112
• 2.2 Removing and installing coolant pump
  116
• 2.3 Removing and installing thermostat
  117
• 3 Radiator, radiator fan
  120
• 3.1 Assembly overview - radiator, radiator fan
  120
• 3.2 Removing and installing radiator
  122
• 3.3 Removing and installing fan mounting with fans
  123
• Mixture preparation - injection
  125
• 1 Injectors
  125
• 1.1 Assembly overview - unit injector
  125
• 1.2 Removing and installing unit injector
  126
• 1.3 Renewing O-rings for unit injectors
  128
• 1.4 Removing and installing prewiring for unit injectors
  130
• 2 Vacuum system
  134
• 2.1 Vacuum hose schematic diagram
  134
• 2.2 Exhaust gas recirculation valve N18 schematic diagram
  135
• 3 Air filter
  136
• 3.1 Assembly overview - air filter housing, engine code BDJ
  136
• 4 Intake manifold
  138
• 4.1 Assembly overview - intake manifold, engine code BDJ
  138
• 5 Engine control unit
  140
• 5.1 Removing and installing engine control unit
  140
• 6 High-pressure pump
  142
• 6.1 Removing and installing tandem pump
  142
• 6.2 Checking delivery pressure of tandem pump
  144
• 6.3 Checking for internal leaks
  146
• Exhaust system
  148
• 1 Exhaust pipes and silencers
  148
• 1.1 Assembly overview - silencers
  148
• 1.2 Separating exhaust pipes from silencers
  149
• 1.3 Aligning exhaust system free of stress
  149
• 1.4 Installation position of clamps
  150
• 2 Exhaust manifold
  151
• 2.1 Assembly overview - exhaust manifold with catalytic converter
  151
• 3 Exhaust gas recirculation
  152
• 3.1 Assembly overview - exhaust gas recirculation, engine code BDJ
  152
• 3.2 Checking exhaust gas recirculation valve
  154
• Glow plug system
  156
• 1 Glow plug system
  156
• 1.1 Removing, installing and checking glow plugs
  156
• 1.2 Removing and installing engine speed sender G28
  157