4-cylinder diesel engine (2.0 l engine, common rail)

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety regulations for working on fuel supply
  1
• 1.2 Safety precautions when working on charge air system
  2
• 1.3 Safety regulations for working on fuel supply
  2
• 1.4 Safety precautions when working on the SCR system
  3
• 1.6 Safety measures when working on vehicles with a start/stop system
  4
• 1.7 Safety precautions when working on fuel system
  4
• 2 Identification
  5
• 2.1 Engine number/engine data
  5
• 3 Repair instructions
  7
• 3.1 Rules for cleanliness when working on fuel supply system
  7
• 3.2 Rules for cleanliness and instructions for working on fuel system
  7
• 3.3 Rules for cleanliness during work on fuel system
  9
• 3.4 Rules for cleanliness when working on the SCR system
  9
• 3.5 General notes on the lubrication system
  10
• 3.6 General notes on cooling system
  10
• 3.7 General notes on fuel system
  11
• 3.8 Notes on hose connections with screw-type clips
  12
• Removing and installing engine
  14
• 1 Removing and installing engine
  14
• 1.1 Removing engine
  14
• 1.2 Securing engine on engine and gearbox support
  24
• 1.3 Removing engine, Crafter 4MOTION with Achleitner four-wheel drive
  25
• 1.4 Installing engine
  36
• 2 Assembly mountings
  38
• 2.1 Assembly overview - assembly mountings
  38
• 2.2 Supporting engine in installation position
  40
• Crankshaft group
  43
• 1 Cylinder block (pulley end)
  43
• 1.1 Assembly overview - poly V-belt drive
  43
• 1.2 Assembly overview - cylinder block (pulley end)
  47
• 1.3 Assembly overview - sealing flange, belt pulley end
  49
• 1.4 Removing and installing poly-V belt
  50
• 1.5 Removing and installing tensioner for poly V-belt
  53
• 1.6 Removing and installing poly V-belt for viscous fan
  54
• 1.7 Removing and installing vibration damper
  57
• 1.8 Removing and installing bracket for ancillaries
  58
• 1.9 Removing and installing bracket with belt pulley
  60
• 1.10 Renewing crankshaft oil seal - belt pulley end
  61
• 1.11 Removing and installing sealing flange on pulley end
  64
• 2 Cylinder block, gearbox end
  69
• 2.1 Assembly overview - cylinder block, gearbox end
  69
• 2.2 Removing and installing flywheel
  70
• 2.3 Removing and installing sealing flange on gearbox side
  71
• 3 Crankshaft
  83
• 3.1 Assembly overview - crankshaft
  83
• 3.2 Renewing needle bearing in crankshaft
  84
• 3.3 Crankshaft dimensions
  86
• 3.4 Measuring axial clearance of crankshaft
  87
• 3.5 Measuring radial clearance of crankshaft
  88
• 4 Auxiliary drive
  89
• 4.1 Assembly overview - ancillary drive
  89
• 4.2 Retrofitting auxiliary drive (genuine parts set)
  97
• 4.3 Removing and installing poly V-belt for auxiliary drive
  101
• 5 Pistons and conrods
  103
• 5.1 Assembly overview - pistons and conrods
  103
• 5.2 Measuring piston projection at TDC
  105
• 5.3 Checking pistons and cylinder bores
  107
• 5.4 Separating new conrod
  110
• 5.5 Checking radial clearance of conrods
  110
• 5.6 Installation position of bearing shells
  111
• Cylinder head, valve gear
  112
• 1 Cylinder head
  112
• 1.1 Assembly overview - cylinder head
  112
• 1.2 Assembly overview - cylinder head cover
  116
• 1.3 Removing and installing cylinder head
  118
• 1.4 Removing and installing cylinder head cover
  130
• 1.5 Removing and installing injector seals
  136
• 1.6 Removing and installing vacuum pump
  137
• 1.7 Checking compression
  139
• 2 Fully enclosing toothed belt guard
  141
• 2.1 Assembly overview - fully enclosing toothed belt guard
  141
• 2.2 Removing and installing upper toothed belt guard (fully enclosing)
  143
• 2.3 Removing and installing lower toothed belt guard (fully enclosed)
  144
• 2.4 Removing and installing rear toothed belt guard (fully enclosing)
  146
• 3 Toothed belt drive
  150
• 3.1 Assembly overview - toothed belt
  150
• 3.2 Removing and installing toothed belt
  152
• 4 Valve gear
  167
• 4.1 Assembly overview - valve gear
  167
• 4.2 Removing and installing valve stem seals
  169
• 4.3 Renewing valve stem seals with cylinder head removed
  174
• 4.4 Removing and installing camshaft
  177
• 4.5 Measuring axial play of camshaft
  186
• 4.6 Measuring radial play of camshaft
  187
• 4.7 Removing and installing camshaft oil seal
  187
• 4.8 Checking hydraulic compensation elements
  192
• 5 Inlet and exhaust valves
  194
• 5.1 Reworking valve seats
  194
• 5.2 Checking valve guides
  194
• 5.3 Checking valves
  195
• 5.4 Valve dimensions
  195
• Lubrication
  196
• 1 Sump, oil pump
  196
• 1.1 Assembly overview - sump/oil pump
  196
• 1.2 Removing and installing oil sump
  199
• 1.3 Removing and installing oil pump
  203
• 1.4 Engine oil:
  204
• 1.5 Removing and installing oil level and oil temperature sender G266
  204
• 1.6 Measuring oil consumption
  205
• 2 Oil filter, oil pressure switch
  206
• 2.1 Assembly overview - oil filter housing with engine oil cooler
  206
• 2.2 Removing and installing engine oil cooler
  208
• 2.3 Removing and installing oil filter housing
  210
• 2.4 Removing and installing oil pressure switch F1
  212
• 2.5 Checking oil pressure switch F1
  213
• 2.6 Checking oil pressure
  215
• 3 Oil circuit
  217
• 3.1 Removing and installing oil supply line, single turbo
  217
• 3.2 Removing and installing oil supply line, bi-turbo
  218
• Cooling
  223
• 1 Cooling system/coolant
  223
• 1.1 Connection diagram - coolant hoses
  223
• 1.2 Draining and adding coolant
  233
• 1.3 Checking cooling system for leaks
  242
• 2 Coolant pump, regulation of cooling system
  245
• 2.1 Assembly overview - coolant pump, thermostat
  245
• 2.2 Assembly overview - electric coolant pump
  245
• 2.3 Removing and installing coolant pump
  246
• 2.4 Removing and installing 4/2-way valve with thermostat
  248
• 2.5 Removing and installing coolant temperature sender G62
  251
• 2.6 Removing and installing radiator outlet coolant temperature sender G83
  252
• 2.7 Removing and installing coolant flange
  253
• 2.8 Removing and installing Y-thermostat
  255
• 2.9 Removing and installing coolant circulation pump V50
  257
• 2.10 Removing and installing 3/2-way valve, Euro 6 vehicles
  258
• 3 Coolant pipes/coolant hoses
  260
• 3.1 Assembly overview - coolant pipe/coolant hose
  260
• 3.2 Removing and installing coolant pipe with coolant hose
  261
• 4 Radiator, radiator fan
  265
• 4.1 Assembly overview - radiator/radiator fan
  265
• 4.2 Assembly overview - viscous fan
  266
• 4.3 Removing and installing viscous fan
  268
• 4.4 Removing and installing cowling
  271
• 4.5 Removing and installing radiator
  272
• Turbocharging/supercharging
  276
• 1 Turbocharger
  276
• 1.1 Assembly overview - turbocharger, single turbo
  276
• 1.2 Assembly overview - turbocharger, bi-turbo
  279
• 1.3 Removing and installing turbocharger, single turbo
  282
• 1.4 Removing and installing turbocharger, bi-turbo
  288
• 1.6 Assembly overview - turbocharger, bi-turbo, dismantling
  303
• 1.7 Renewing gasket between bi-turbo turbine housings
  306
• 1.8 Removing and installing regulating flap potentiometer G584
  310
• 1.9 Renewing vacuum unit for turbocharger
  317
• 2 Charge air system
  324
• 2.1 Assembly overview - charge air system
  324
• 2.2 Removing and installing charge air cooler
  326
• 2.5 Removing and installing charge pressure control solenoid valve N75
  328
• 2.6 Removing and installing exhaust gas flap valve N220
  329
• 2.7 Removing and installing charge air pipe
  330
• 2.8 Checking charge air system for leaks
  332
• Mixture preparation - injection
  336
• 1 Injection system
  336
• 1.1 Schematic overview - fuel system
  336
• 1.2 Overview of fitting locations - injection system
  338
• 1.3 Checking fuel system for leaks
  345
• 2 Vacuum system
  346
• 2.1 Connection diagram - vacuum system
  346
• 3 Intake manifold
  349
• 3.1 Assembly overview – intake manifold
  349
• 3.2 Removing and installing intake manifold
  350
• 3.3 Removing and installing throttle valve module J338
  354
• 4 Air filter
  356
• 4.1 Assembly overview - air filter housing
  356
• 4.2 Removing and installing air filter housing
  357
• 5 Injectors/high-pressure accumulator (rail)
  358
• 5.1 Assembly overview - injectors
  358
• 5.2 Removing and installing injectors
  361
• 5.3 Adapting correction values for injectors
  366
• 5.4 Testing injectors
  367
• 5.5 Testing jammed-open injectors
  367
• 5.6 Checking return flow rate of injectors with engine running
  369
• 5.7 Checking return flow rate of injectors at starter speed
  372
• 5.8 Removing and installing fuel rail
  374
• 5.9 Removing and installing high-pressure lines
  377
• 6 Senders and sensors
  381
• 6.1 Removing and installing fuel pressure regulating valve N276
  381
• 6.2 Checking fuel pressure regulating valve N276
  383
• 6.3 Removing and installing fuel pressure sender G247
  384
• 6.4 Removing and installing air mass meter G70
  387
• 7 Engine control unit
  389
• 7.1 Removing and installing engine control unit J623
  389
• 7.2 Removing and installing engine (motor) control unit J623 with protective housing
  390
• 8 High-pressure pump
  392
• 8.1 Assembly overview - high-pressure pump
  392
• 8.2 Removing and installing high-pressure pump
  394
• 8.3 Initial fuel filling after installation of the high-pressure pump
  397
• 8.4 Checking high-pressure pump
  398
• 9 Lambda probe
  401
• 9.1 Removing and installing Lambda probe
  401
• Exhaust system
  405
• 1 Exhaust pipes and silencers
  405
• 1.1 Assembly overview – silencers
  405
• 1.5 Checking exhaust system for leaks
  409
• 1.6 Removing and installing rear silencer
  409
• 2 Emission control
  418
• 2.1 Assembly overview – emission control
  418
• 2.2 Removing and installing particulate filter
  420
• 3 SCR system (selective catalytic reduction)
  428
• 3.1 Assembly overview – reducing agent tank
  428
• 3.2 Removing and installing reducing agent tank
  430
• 3.3 Removing and installing reducing agent supply line
  432
• 3.4 Removing and installing injector for reduction agent N474
  435
• 3.5 Removing and installing control unit for reducing-agent heater J891
  436
• 3.6 Removing and installing delivery unit for reducing agent metering system GX19
  437
• 3.7 Draining reducing agent tank
  441
• 3.8 Removing and installing filler neck for reducing agent
  444
• 3.9 Removing and installing NOx sender G295/control unit for NOx sender J583
  445
• 3.10 Removing and installing NOx sender 2 G687/control unit for NOx sender 2 J881
  447
• 3.11 Removing and installing exhaust gas temperature sender 2 G448
  450
• 4 Exhaust gas recirculation
  453
• 4.1 Assembly overview – exhaust gas recirculation
  453
• 4.2 Removing and installing exhaust gas recirculation valve N18
  454
• 4.3 Removing and installing exhaust gas recirculation cooler
  455
• 4.4 Checking exhaust gas recirculation cooler for leaks
  458
• 4.5 Removing and installing pump for exhaust gas recirculation cooler V400
  462
• 4.6 Removing and installing exhaust gas recirculation temperature sensor G98
  463
• Glow plug system
  465
• 1 Glow plug system
  465
• 1.1 Removing and installing glow plug
  465
• 1.2 Checking glow plug system
  467
• 1.3 Removing and installing Hall sender G40
  467
• 1.4 Removing and installing engine speed sender G28
  469