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

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
  9
• 1.3 Notes on installing
  10
• 1.4 Assembly mountings
  11
• Crankshaft group
  12
• 1 Dismantling and assembling engine
  12
• 1.1 Assembly overview - poly V-belt drive
  12
• 1.2 Removing and installing poly V-belt
  13
• 1.3 Assembly overview - toothed belt drive
  15
• 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
  20
• 2.3 Removing and installing sealing flange - pulley end
  22
• 2.4 Renewing crankshaft sealing flange - flywheel end
  25
• 2.5 Removing and installing engine speed sender G28
  32
• 3 Crankshaft
  34
• 3.1 Assembly overview - crankshaft
  34
• 3.2 Crankshaft dimensions
  35
• 3.3 Pulling needle bearing out of and driving into crankshaft
  35
• 4 Pistons and conrods
  37
• 4.1 Assembly overview - pistons and conrods
  37
• 4.2 Separating new conrods
  39
• 4.3 Checking piston projection at TDC
  40
• 4.4 Piston and cylinder dimensions
  41
• 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 belt
  47
• 1.4 Removing and installing cylinder head
  60
• 1.5 Checking compression
  64
• 2 Valve gear
  67
• 2.1 Assembly overview - valve gear
  67
• 2.2 Checking valve guides
  69
• 2.3 Renewing valve stem seals
  70
• 2.4 Removing and installing camshaft
  72
• 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, balancer shaft module with chain drive
  81
• 2.2 Removing and installing oil pump (for balancer shaft module with chain drive)
  83
• 2.3 Removing and installing balancer shaft module with chain drive
  86
• 2.4 Retrofitting spur gear drive for balancer shaft module
  90
• 2.6 Removing and installing oil pump (for balancer shaft module with spur gear drive)
  96
• 2.7 Removing balancer shaft module with spur gear drive
  96
• 2.8 Renewing spur gear for crankshaft
  97
• 2.9 Installing balancer shaft module with spur gear drive
  100
• 2.10 Removing and installing oil sump
  106
• 3 Oil filter bracket, oil pressure and oil cooler
  109
• 3.1 Assembly overview - oil filter bracket and oil cooler
  109
• 3.2 Checking oil pressure and oil pressure switch
  110
• Cooling
  112
• 1 Parts of cooling system
  112
• 1.1 Assembly overview - parts of cooling system, body side
  112
• 1.2 Assembly overview - cooling system, engine side
  114
• 1.3 Coolant hose schematic diagram
  116
• 1.4 Draining and filling coolant
  117
• 1.5 Removing and installing fan mounting with fans
  120
• 1.6 Removing and installing radiator
  121
• 1.7 Removing and installing coolant pump
  122
• 1.8 Removing and installing thermostat
  123
• 1.9 Checking cooling system for leaks
  125
• 1.10 Checking oil cooler for leaks
  127
• Fuel supply system
  130
• 1 Fuel tank, vehicles with all-wheel drive
  130
• 1.1 Assembly overview - fuel tank
  130
• 1.2 Emptying fuel tank
  132
• 1.3 Removing and installing fuel tank
  135
• 1.4 Removing and installing fuel gauge sender 2 G169
  140
• 1.5 Removing and installing suction-jet pump
  143
• 2 Fuel tank, vehicles with front-wheel drive
  145
• 2.1 Assembly overview - fuel tank
  145
• 2.2 Emptying fuel tank
  147
• 2.3 Removing and installing fuel tank
  149
• 2.4 Removing and installing fuel delivery unit
  152
• 2.5 Removing and installing fuel gauge sender
  154
• 2.6 Checking fuel pump
  154
• 3 Parts of fuel supply system
  160
• 3.1 Safety precautions when working on fuel supply system
  160
• 3.2 Rules for cleanliness
  160
• 3.3 Assembly overview - fuel filter
  161
• 3.4 Removing and installing fuel cooler
  163
• 3.5 Assembly overview - accelerator mechanism
  164
• 3.6 Checking tandem pump
  166
• 3.7 Removing and installing tandem pump
  170
• Turbocharging/supercharging
  174
• 1 Charge air system with turbocharger
  174
• 1.1 Safety precautions
  174
• 1.2 Rules for cleanliness
  174
• 1.3 Hose connections
  175
• 1.4 Assembly overview - turbocharger
  176
• 1.5 Removing and installing turbocharger
  178
• 1.6 Assembly overview - charge air cooling
  179
• 1.7 Vacuum hose schematic diagram
  181
• 1.8 Checking charge air system for leaks
  181
• Mixture preparation - injection
  184
• 1 Diesel direct injection system
  184
• 1.1 Safety precautions
  184
• 1.2 Rules for cleanliness
  185
• 1.3 Assembly overview - unit injector
  185
• 1.4 Removing and installing O-rings for unit injector
  186
• 1.5 Removing and installing unit injector
  188
• 1.6 Assembly overview - intake manifold with intake manifold flap motor
  190
• 1.7 Assembly overview - air filter
  192
• 2 Engine control unit
  193
• 2.1 Reading and erasing engine control unit fault memory
  193
• 2.2 Removing and installing engine control unit
  194
• 2.3 Removing and installing anti-theft engine control unit
  195
• Exhaust system
  199
• 1 Parts of exhaust system
  199
• 1.1 Assembly overview - front exhaust pipe with particulate filter
  199
• 1.2 Assembly overview - silencer, vehicles with front-wheel drive
  201
• 1.3 Assembly overview - silencer, vehicles with all-wheel drive
  202
• 1.4 Aligning exhaust system free of stress
  202
• 2 Exhaust gas recirculation system
  204
• 2.1 Assembly overview - exhaust gas recirculation
  204
• 2.2 Assembly overview - exhaust gas recirculation cooler
  205
• Glow plug system
  206
• 1 Checking glow plug system
  206
• 1.1 Characteristics of ceramic glow plugs
  206
• 1.2 Removing, installing and checking ceramic glow pin plugs
  206