4-cylinder diesel engine (2.0 l engine, 4 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
  8
• 1.3 Notes on installing
  8
• 1.4 Assembly mountings
  9
• Crankshaft group
  11
• 1 Dismantling and assembling engine
  11
• 1.1 Assembly overview - poly-V-belt drive
  11
• 1.2 Removing and installing poly-V-belt
  12
• 1.3 Assembly overview - poly-V-belt drive
  14
• 1.4 Assembly overview - crankcase
  15
• 2 Removing and installing sealing flange and flywheel
  17
• 2.1 Renewing crankshaft sealing flange - flywheel end
  18
• 2.2 Renewing crankshaft oil seal - pulley end
  25
• 2.3 Removing and installing sealing flange - pulley end
  27
• 2.4 Removing and installing engine speed sender G28
  29
• 3 Pistons and conrods
  30
• 3.1 Assembly overview - pistons and conrods
  30
• 3.2 Piston and cylinder dimensions
  32
• 3.3 Checking piston projection at TDC
  32
• 4 Crankshaft
  35
• 4.1 Assembly overview - crankshaft
  35
• 4.2 Crankshaft dimensions
  35
• 4.3 Pulling needle bearing out of and driving into crankshaft
  36
• Cylinder head, valve gear
  38
• 1 Cylinder head
  38
• 1.1 Assembly overview - cylinder head
  38
• 1.2 Removing and installing cylinder head cover
  40
• 1.3 Removing, installing and tensioning toothed belts
  41
• 1.4 Removing and installing cylinder head
  50
• 1.5 Checking compression
  55
• 2 Valve gear
  56
• 2.1 Assembly overview - valve gear
  56
• 2.2 Removing and installing roller rocker fingers
  58
• 2.3 Valves
  60
• 2.4 Removing and installing camshafts
  63
• 2.5 Removing and installing camshaft oil seal
  67
• Lubrication
  69
• 1 Engine oil
  69
• 1.1 Oil capacities
  69
• 1.2 Checking engine oil level
  69
• 2 Parts of lubrication system
  70
• 2.1 Assembly overview - oil pump, sump
  70
• 2.2 Removing and installing oil sump
  71
• 3 Oil filter holder, oil pressure, oil cooler and oil supply line
  74
• 3.1 Assembly overview - oil filter holder and oil cooler
  74
• 3.2 Checking oil pressure and oil pressure switch
  75
• 3.3 Assembly overview - oil supply line to turbocharger
  77
• 3.4 Removing and installing oil supply line to turbocharger
  77
• Cooling
  79
• 1 Parts of cooling system
  79
• 1.1 Assembly overview - parts of cooling system, body side
  80
• 1.2 Assembly overview - parts of cooling system, engine side
  81
• 1.3 Coolant hose schematic diagram
  83
• 1.4 Removing and installing radiator
  85
• 1.5 Removing and installing coolant pump
  86
• 1.6 Removing and installing thermostat
  88
• 1.7 Draining and filling coolant
  90
• 1.8 Checking cooling system for leaks
  93
• 1.9 Checking oil cooler for leaks
  95
• Fuel supply system
  97
• 1 Safety precautions when working on fuel supply system
  97
• 2 Rules for cleanliness
  98
• 3 Fuel tank, vehicles with front-wheel drive
  99
• 3.1 Assembly overview - fuel tank
  99
• 3.2 Emptying fuel tank
  100
• 3.3 Removing and installing fuel tank
  102
• 4 Fuel tank, vehicles with four-wheel drive
  105
• 4.1 Assembly overview - fuel tank
  106
• 4.2 Emptying fuel tank
  107
• 4.3 Removing and installing fuel tank
  109
• 4.4 Removing and installing fuel gauge sender 2 G169
  112
• 4.5 Removing and installing suction jet pump
  114
• 5 Repairing fuel supply system
  115
• 5.1 Checking tandem pump
  115
• 5.2 Removing and installing tandem pump
  117
• 5.3 Assembly overview - fuel filter
  120
• 5.4 Removing and installing fuel cooler
  121
• 5.5 Assembly overview - accelerator mechanism
  122
• 5.6 Removing and installing fuel sender
  122
• 5.7 Checking fuel pump
  123
• 5.8 Removing and installing fuel cooler
  124
• 5.9 Removing and installing fuel delivery unit
  125
• Turbocharging/supercharging
  128
• 1 Charge air system with turbocharger
  128
• 1.1 Safety precautions
  128
• 1.2 Rules for cleanliness
  128
• 1.3 Hose connections
  129
• 1.4 Assembly overview - turbocharger with attachments
  130
• 1.5 Removing and installing turbocharger
  133
• 1.6 Assembly overview - parts of charge air cooling
  134
• 1.7 Checking charge air system for leaks
  136
• Mixture preparation - injection
  139
• 1 Diesel direct injection system
  139
• 1.1 Safety precautions
  139
• 1.2 Rules for cleanliness
  139
• 1.3 Assembly overview - intake manifold with attachments
  141
• 1.4 Assembly overview - pre-wired wiring harness for unit injectors and glow plugs
  143
• 1.5 Removing and installing prewiring for unit injectors and glow plugs
  143
• 1.6 Assembly overview - unit injector
  146
• 1.7 Removing and installing unit injector
  147
• 1.8 Removing and installing O-rings for unit injector
  150
• 1.9 Assembly overview - air filter
  152
• 2 Engine control unit
  153
• 2.1 Reading and erasing engine control unit fault memory
  153
• 2.2 Adapting functions and components
  154
• 2.3 Removing and installing engine control unit
  154
• Exhaust system
  156
• 1 Exhaust system, vehicles with front-wheel drive
  156
• 1.1 Assembly overview - front exhaust pipe with catalytic converter
  156
• 1.2 Assembly overview - front exhaust pipe with particulate filter
  158
• 1.3 Assembly overview - silencers
  160
• 1.4 Cutting exhaust pipe
  161
• 1.5 Aligning exhaust system stress free
  162
• 2 Exhaust system, vehicles with four-wheel drive
  163
• 2.1 Assembly overview - exhaust system
  163
• 2.2 Aligning exhaust system stress free
  163
• 3 Exhaust gas recirculation system
  165
• 3.1 Assembly overview - parts of exhaust gas recirculation
  165
• 3.2 Vacuum hose schematic diagram
  167
• Glow plug system
  169
• 1 Removing and installing glow plugs
  169