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
  4
• 1.2 Securing engine to assembly stand
  8
• 1.3 Notes on installing
  9
• 1.4 Assembly mountings
  10
• Crankshaft group
  11
• 1 Dismantling and assembling engine
  11
• 1.1 Assembly overview - poly-V-belt drive
  12
• 1.2 Removing and installing poly-V-belt
  12
• 1.3 Assembly overview - toothed belt drive
  15
• 1.4 Assembly overview - cylinder block
  16
• 2 Sealing flange and flywheel
  18
• 2.1 Assembly overview - sealing flange and flywheel
  18
• 2.2 Renewing crankshaft oil seal - belt pulley end
  19
• 2.3 Removing and installing sealing flange - pulley end
  22
• 2.4 Renewing crankshaft sealing flange - flywheel end
  24
• 2.5 Removing and installing engine speed sender G28
  31
• 3 Crankshaft
  32
• 3.1 Assembly overview - crankshaft
  32
• 3.2 Crankshaft dimensions
  33
• 3.3 Pulling needle bearing out of and driving into crankshaft
  33
• 4 Pistons and conrods
  35
• 4.1 Assembly overview - pistons and conrods
  35
• 4.2 Piston and cylinder dimensions
  37
• 4.3 Checking piston projection at TDC
  38
• Cylinder head, valve gear
  40
• 1 Cylinder head
  40
• 1.1 Assembly overview - cylinder head
  40
• 1.2 Removing and installing cylinder head cover
  42
• 1.3 Removing, installing and tensioning toothed belt
  43
• 1.4 Removing and installing cylinder head
  51
• 1.5 Checking compression
  56
• 2 Valve gear
  57
• 2.1 Assembly overview - valve gear
  57
• 2.2 Removing and installing roller rocker fingers
  59
• 2.3 Valve dimensions
  61
• 2.4 Checking valve guides
  61
• 2.5 Renewing valve stem oil seals
  62
• 2.6 Removing and installing camshafts
  64
• 2.7 Removing and installing camshaft oil seal
  68
• Lubrication
  70
• 1 Engine oil
  70
• 1.1 Oil capacities
  70
• 1.2 Checking engine oil level
  70
• 2 Parts of lubrication system
  71
• 2.1 Assembly overview - oil pump, sump, balancer shaft module with chain drive
  72
• 2.2 Removing and installing oil pump (for balancer shaft module with chain drive)
  74
• 2.3 Removing and installing balancer shaft module with chain drive
  77
• 2.5 Removing and installing oil pump (for balancer shaft module with spur gear drive)
  83
• 2.6 Removing balancer shaft module with spur gear drive
  83
• 2.7 Installing balancer shaft module
  85
• 2.8 Removing and installing sump
  89
• 3 Oil filter bracket, oil pressure, oil cooler and oil supply line
  92
• 3.1 Assembly overview - oil filter bracket and oil cooler
  92
• 3.2 Assembly overview - oil supply line to turbocharger
  93
• 3.3 Removing and installing oil supply line to turbocharger
  93
• 3.4 Checking oil pressure and oil pressure switch
  96
• Cooling
  98
• 1 Removing and installing parts of cooling system
  98
• 1.1 Assembly overview - parts of cooling system, body side
  99
• 1.2 Assembly overview - parts of cooling system, engine side
  100
• 1.3 Coolant hose schematic diagram
  101
• 1.4 Draining and filling coolant
  104
• 1.5 Removing and installing fan support with fans
  106
• 1.6 Removing and installing radiator
  107
• 1.7 Removing and installing coolant pump
  108
• 1.8 Removing and installing thermostat
  110
• 1.9 Checking cooling system for leaks
  112
• 1.10 Checking oil cooler for leaks
  114
• Fuel supply system
  116
• 1 Fuel tank, vehicles with four-wheel drive
  116
• 1.1 Assembly overview - fuel tank
  116
• 1.2 Emptying fuel tank
  118
• 1.3 Removing and installing fuel tank
  121
• 1.4 Removing and installing fuel gauge sender 2 G169
  126
• 1.5 Removing and installing suction-jet pump
  129
• 2 Fuel tank, vehicles with front-wheel drive
  131
• 2.1 Assembly overview - fuel tank
  131
• 2.2 Emptying fuel tank
  133
• 2.3 Removing and installing fuel tank
  135
• 2.4 Removing and installing fuel delivery unit
  138
• 2.5 Removing and installing fuel gauge sender
  140
• 2.6 Checking fuel pump
  140
• 3 Parts of fuel system
  143
• 3.1 Safety precautions when working on fuel supply system
  143
• 3.2 Rules for cleanliness
  144
• 3.3 Assembly overview - fuel filter
  144
• 3.4 Removing and installing fuel cooler
  145
• 3.5 Assembly overview - accelerator module
  146
• 3.6 Checking tandem pump
  147
• 3.7 Removing and installing tandem pump
  151
• Turbocharging/supercharging
  154
• 1 Charge air system with turbocharger
  154
• 1.1 Safety precautions
  154
• 1.2 Rules for cleanliness
  154
• 1.3 Hose connections
  155
• 1.4 Assembly overview - turbocharger
  156
• 1.5 Removing and installing turbocharger
  159
• 1.6 Assembly overview - charge air cooling
  160
• 1.7 Checking charge air system for leaks
  162
• Mixture preparation - injection
  165
• 1 Diesel direct injection system
  165
• 1.1 Safety precautions
  165
• 1.2 Rules for cleanliness
  166
• 1.3 Assembly overview - pre-wired wiring harness for unit injectors and glow plugs
  167
• 1.4 Removing and installing pre-wired wiring harness for unit injectors and glow plugs
  167
• 1.5 Assembly overview - unit injector
  170
• 1.6 Removing and installing unit injector
  172
• 1.7 Removing and installing O-rings for unit injector
  175
• 1.8 Assembly overview - intake manifold with intake manifold flap motor
  177
• 1.9 Assembly overview - air filter
  179
• 2 Engine control unit
  180
• 2.1 Reading and erasing engine control unit fault memory
  180
• 2.2 Removing and installing engine control unit
  181
• 2.3 Removing and installing anti-theft engine control unit
  182
• Exhaust system
  186
• 1 Exhaust system
  186
• 1.1 Assembly overview - front exhaust pipe with catalytic converter
  187
• 1.2 Assembly overview - front exhaust pipe with particulate filter
  188
• 1.3 Assembly overview - silencer, vehicle with front-wheel drive
  190
• 1.4 Assembly overview - silencer, vehicle with four-wheel drive
  191
• 1.5 Aligning exhaust system stress free
  191
• 2 Exhaust gas recirculation system
  193
• 2.1 Assembly overview - exhaust gas recirculation
  194
• 2.2 Schematic diagram for vacuum hoses
  195
• Glow plug system
  197
• 1 Checking glow plug system
  197
• 1.1 Characteristics of ceramic glow plugs
  197
• 1.2 Removing, installing and checking ceramic glow plugs
  198