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
  3
• 1.2 Securing engine to assembly stand
  7
• 1.3 Notes on installing
  7
• 1.4 Assembly mountings
  10
• 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
  14
• 1.3 Assembly overview - toothed belt drive
  15
• 1.4 Assembly overview - crankcase
  17
• 2 Sealing flanges 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 drive plate
  33
• 3 Crankshaft
  35
• 3.1 Assembly overview - crankshaft
  35
• 3.2 Crankshaft dimensions
  36
• 4 Pistons and conrods
  37
• 4.1 Assembly overview - pistons and conrods
  37
• 4.2 Separating new conrod
  40
• 4.3 Piston and cylinder dimensions
  41
• 4.4 Checking piston projection at TDC
  41
• Cylinder head, valve gear
  43
• 1 Cylinder head
  43
• 1.1 Assembly overview - cylinder head
  43
• 1.2 Removing and installing cylinder head cover
  46
• 1.3 Removing, installing and tensioning toothed belt
  48
• 1.4 Removing and installing cylinder head
  55
• 1.5 Checking compression
  60
• 2 Valve gear
  63
• 2.1 Assembly overview - valve gear
  63
• 2.2 Checking valve guides
  65
• 2.3 Renewing valve stem seals
  66
• 2.4 Removing and installing camshaft
  68
• 2.5 Removing and installing camshaft oil seal
  72
• Lubrication
  75
• 1 Engine oil
  75
• 1.1 Oil capacities
  75
• 1.2 Checking engine oil level
  75
• 2 Parts of lubrication system
  76
• 2.1 Assembly overview - oil pump, sump, balancer shaft module
  76
• 2.2 Removing and installing oil sump
  79
• 2.3 Removing and installing oil pump
  81
• 2.4 Remove balancer shaft module
  82
• 2.5 Renewing spur gear for crankshaft
  84
• 2.6 Installing balancer shaft module
  86
• 3 Oil filter bracket, oil pressure, oil cooler and oil supply line
  93
• 3.1 Assembly overview - oil filter bracket and oil cooler
  93
• 3.2 Assembly overview - oil supply line to turbocharger
  94
• 3.3 Removing and installing oil supply line to turbocharger
  94
• 3.4 Checking oil pressure and oil pressure switch
  97
• Cooling
  99
• 1 Removing and installing parts of cooling system
  99
• 1.1 Assembly overview - parts of cooling system, body side
  99
• 1.2 Assembly overview - cooling system, engine side
  101
• 1.3 Coolant hose schematic diagram
  103
• 1.4 Draining and filling coolant
  104
• 1.5 Removing and installing radiator and fan
  107
• 1.6 Removing and installing coolant pump
  109
• 1.7 Removing and installing thermostat
  110
• 1.8 Checking cooling system for leaks
  112
• 1.9 Checking oil cooler for leaks
  113
• Fuel supply system
  116
• 1 Removing and installing parts of fuel supply system
  116
• 1.1 Safety precautions when working on fuel supply system
  117
• 1.2 Rules for cleanliness
  117
• 1.3 Assembly overview - fuel tank
  117
• 1.4 Assembly overview - fuel filter
  120
• 1.5 Removing and installing fuel cooler
  121
• 1.6 Emptying fuel tank
  122
• 1.7 Removing and installing fuel delivery unit
  125
• 1.8 Removing and installing fuel gauge sender
  127
• 1.9 Checking fuel pump
  127
• 1.10 Checking tandem pump
  128
• 1.11 Removing and installing tandem pump
  132
• 1.12 Assembly overview - accelerator mechanism
  134
• 2 Additive tank
  136
• 2.1 Safety precautions when working on additive tank
  136
• 2.2 Removing and installing additive tank
  136
• 2.3 Assembly overview - additive tank
  137
• Turbocharging/supercharging
  140
• 1 Charge air system with turbocharger
  140
• 1.1 Safety precautions
  140
• 1.2 Rules for cleanliness
  141
• 1.3 Hose connections with quick-release connectors
  141
• 1.4 Assembly overview - turbocharger
  141
• 1.5 Assembly overview - charge air cooling
  143
• 1.6 Checking charge air system for leaks
  145
• 1.7 Charge pressure control hose routing diagram
  146
• Mixture preparation - injection
  148
• 1 Repairing diesel direct injection system
  148
• 1.1 Safety precautions
  148
• 1.2 Rules for cleanliness
  149
• 1.3 General notes on injection
  149
• 1.4 Assembly overview - intake manifold with intake manifold flap motor
  149
• 1.5 Assembly overview - air filter
  151
• 1.6 Assembly overview - unit injector
  151
• 1.7 Removing and installing O-rings for unit injector
  152
• 1.8 Removing and installing unit injector
  153
• 2 Engine control unit
  157
• 2.1 Removing and installing engine control unit
  157
• Exhaust system
  159
• 1 Removing and installing parts of exhaust system
  159
• 1.1 Exhaust system for vehicles without particulate filter
  159
• 1.2 Exhaust system for vehicles with particulate filter
  161
• 2 Exhaust gas recirculation system
  164
• 2.1 Assembly overview - exhaust gas recirculation
  164
• Glow plug system
  165
• 1 Checking glow plug system
  165
• 1.1 Characteristics of ceramic glow plugs
  165
• 1.2 Removing, installing and checking ceramic glow pin plugs
  165