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
  18
• 1.3 Installing engine
  20
• 1.4 Checking and adjusting assembly mounting
  22
• 1.5 Assembly mounting - Torque settings
  25
• Crankshaft group
  27
• 1 Dismantling and assembling engine
  27
• 1.1 Assembly overview - poly-V-belt drive
  27
• 1.2 Assembly overview - toothed belt drive
  28
• 1.3 Cylinder block - Assembly overview
  29
• 1.4 Removing and installing poly-V-belt
  30
• 2 Removing and installing sealing flange and flywheel
  33
• 2.1 Assembly overview
  33
• 2.2 Renewing crankshaft oil seal - belt pulley end
  34
• 2.3 Removing and installing sealing flange - pulley end
  36
• 2.4 Renewing crankshaft sealing flange - flywheel end
  38
• 2.5 Removing and installing two-part flywheel
  45
• 2.6 Removing and installing engine speed sender G28
  47
• 3 Crankshaft
  49
• 3.1 Assembly overview - crankshaft
  49
• 3.2 Crankshaft dimensions
  50
• 3.3 Marking on crankshaft bearing top
  50
• 3.4 Pulling needle bearing out of and driving into crankshaft
  50
• 4 Pistons and conrods
  53
• 4.1 Assembly overview - pistons and conrods
  53
• 4.2 Checking piston projection at TDC
  54
• 4.3 Piston and cylinder dimensions
  55
• 4.4 Piston rings, cylinder bore and piston installation position
  56
• Cylinder head, valve gear
  58
• 1 Cylinder head
  58
• 1.1 Assembly overview - cylinder head
  58
• 1.2 Removing and installing cylinder head cover
  60
• 1.3 Removing, installing and tensioning toothed belt
  61
• 1.4 Removing and installing cylinder head
  70
• 1.5 Checking compression
  78
• 2 Valve gear
  79
• 2.1 Assembly overview - valve gear
  79
• 2.2 Checking camshaft axial clearance
  82
• 2.3 Removing and installing roller rocker fingers
  82
• 2.4 Valves
  83
• 2.5 Renewing valve stem seals
  84
• 2.6 Removing and installing camshafts
  86
• 2.7 Removing and installing camshaft oil seal
  90
• 2.8 Checking hydraulic tappets
  92
• Lubrication
  94
• 1 Engine oil
  94
• 1.1 Oil capacities
  94
• 1.2 Checking engine oil level
  94
• 2 Parts of lubrication system
  95
• 2.1 Assembly overview - oil pump, sump
  95
• 2.2 Removing and installing sump
  97
• 2.3 Removing and installing oil pump
  99
• 3 Oil filter bracket, oil pressure, oil cooler and oil supply pipe
  100
• 3.1 Assembly overview - oil filter bracket and oil cooler
  100
• 3.2 Removing and installing oil filter bracket with oil cooler
  101
• 3.3 Checking oil pressure and oil pressure switch
  105
• 3.4 Oil supply pipe to turbocharger - Assembly overview
  107
• 3.5 Removing and installing oil supply line to turbocharger
  108
• Cooling
  111
• 1 Parts of cooling system
  111
• 1.1 Assembly overview - parts of cooling system, body side
  112
• 1.2 Assembly overview - parts of cooling system, engine side
  113
• 1.3 Coolant hose schematic diagram
  114
• 1.4 Draining and filling coolant
  117
• 1.5 Removing and installing radiator fan V7 and radiator fan 2 V177
  120
• 1.6 Removing and installing radiator
  121
• 1.7 Removing and installing coolant pump
  123
• 1.8 Removing and installing thermostat
  125
• 1.9 Checking cooling system for leaks
  128
• 1.10 Checking oil cooler for leaks
  129
• Fuel supply system
  132
• 1 Parts of fuel system
  132
• 1.1 Safety precautions when working on fuel supply system
  132
• 1.2 Rules for cleanliness
  133
• 1.3 Assembly overview - fuel tank
  133
• 1.4 Emptying fuel tank
  135
• 1.5 Removing and installing fuel tank
  137
• 1.6 Assembly overview - fuel filter
  140
• 1.7 Removing and installing fuel cooler
  142
• 1.8 Removing and installing fuel delivery unit
  143
• 1.9 Removing and installing fuel gauge sender G
  145
• 1.10 Removing and installing tandem pump
  146
• 1.11 Checking tandem pump
  148
• 1.12 Checking fuel pump
  153
• 2 Electronic power control (EPC)
  156
• 2.1 Function of EPC system
  156
• 2.2 Accelerator pedal module - Assembly overview
  156
• 2.3 Removing and installing accelerator pedal module
  157
• Turbocharging/supercharging
  159
• 1 Charge air system with turbocharger: Engine codes AZV, BKD
  159
• 1.1 General notes
  159
• 1.2 Safety precautions
  160
• 1.3 Rules for cleanliness
  160
• 1.4 Charge pressure control schematic diagram
  160
• 1.5 Solenoid valve block schematic diagram
  161
• 1.6 Assembly overview - turbocharger with attachments
  162
• 1.7 Removing and installing turbocharger
  163
• 1.8 Assembly overview - parts of charge air cooling
  168
• 1.9 Removing and installing charge air cooler
  169
• 1.10 Installing hose connections with connector couplings
  170
• 1.11 Checking charge air system for leaks
  171
• 2 Charge air system with turbocharger: Engine code BMN
  174
• 2.1 General notes
  174
• 2.2 Safety precautions
  174
• 2.3 Rules for cleanliness
  175
• 2.4 Charge pressure control schematic diagram
  175
• 2.5 Assembly overview - turbocharger with attachments
  176
• 2.6 Removing and installing turbocharger
  178
• 2.7 Assembly overview - parts of charge air cooling
  179
• 2.8 Removing and installing charge air cooler
  180
• 2.9 Installing hose connections with connector couplings
  181
• 2.10 Checking charge air system for leaks
  182
• Mixture preparation - injection
  185
• 1 Diesel direct injection system
  185
• 1.1 Safety precautions
  186
• 1.2 Rules for cleanliness
  186
• 1.3 Removing and installing intake manifold flap motor V157
  187
• 1.5 Assembly overview - intake manifold with attachments: engine code BMN
  191
• 1.6 Removing and installing intake manifold
  191
• 1.7 Pre-wiring for unit injector - Assembly overview
  195
• 1.8 Removing and installing pre-wired wiring harness for unit injectors and glow plugs
  195
• 1.9 Assembly overview - unit injector
  198
• 1.10 Removing and installing unit injector
  200
• 1.11 Removing and installing O-rings for unit injector
  203
• 1.12 Assembly overview - air filter
  204
• 1.13 Removing and installing automatic glow period control unit J179
  204
• 2 Engine control unit
  208
• 2.1 Reading and clearing engine control unit fault memory
  208
• 2.2 Removing and installing engine control unit
  209
• Exhaust system
  213
• 1 Exhaust system
  213
• 1.1 Assembly overview - front exhaust pipe with catalytic converter
  215
• 1.2 Assembly overview - front exhaust pipe with particulate filter
  216
• 1.3 Assembly overview - silencer with mountings
  218
• 1.4 Removing and installing front exhaust pipe with catalytic converter
  219
• 1.5 Removing and installing front exhaust pipe with particulate filter
  220
• 1.6 Connecting and disconnecting front and rear silencers
  222
• 1.7 Aligning exhaust system free of stress
  223
• 2 Exhaust gas recirculation system
  225
• 2.2 Parts of exhaust gas recirculation - assembly overview: engine code BMN
  227
• 2.3 Checking mechanical exhaust gas recirculation valve: engine codes AZV, BKD
  227
• 2.5 Removing and installing exhaust gas recirculation radiator, engine code BMN
  231
• Glow plug system
  234
• 1 Checking glow plug system
  234
• 1.1 Removing and installing glow plugs
  234
• 1.2 Characteristics of ceramic glow plugs
  235
• 1.3 Removing, installing and checking ceramic glow plugs
  235