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

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety precautions when working on fuel system
  1
• 1.2 Safety regulations for working on fuel supply
  2
• 1.3 Safety precautions when working on the cooling system
  3
• 2 Identification
  5
• 2.1 Engine number/engine data
  5
• 3 Repair instructions
  7
• 3.1 General notes
  7
• 3.2 Rules for cleanliness
  8
• 3.3 Instructions for working on fuel system
  8
• 3.4 Notes on hose connections with screw-type clips
  10
• Removing and installing engine
  12
• 1 Removing and installing engine
  12
• 1.1 Removing engine
  12
• 1.2 Securing engine on engine and gearbox support
  28
• 1.3 Installing engine
  30
• 2 Assembly mountings
  34
• 2.1 Assembly overview - assembly mountings
  34
• Crankshaft group
  38
• 1 Cylinder block (pulley end)
  38
• 1.1 Assembly overview - cylinder block (pulley end)
  38
• 1.2 Assembly overview - sealing flange, belt pulley end
  40
• 1.3 Assembly overview - poly V-belt drive
  41
• 1.4 Assembly overview - cover for poly V-belt
  47
• 1.5 Removing and installing poly-V belt
  47
• 1.6 Removing and installing tensioner for poly V-belt
  50
• 1.7 Removing and installing bracket for ancillaries
  51
• 1.8 Removing and installing vibration damper
  52
• 1.9 Renewing crankshaft oil seal - belt pulley end
  53
• 1.10 Removing and installing sealing flange on pulley end
  56
• 1.11 Removing and installing cover for poly V-belt
  60
• 2 Cylinder block, gearbox end
  62
• 2.1 Assembly overview - cylinder block, gearbox end
  62
• 2.2 Removing and installing flywheel
  64
• 2.3 Removing and installing sealing flange on gearbox side
  66
• 2.4 Removing and installing drive plate
  85
• 3 Crankshaft
  88
• 3.1 Assembly overview - crankshaft
  88
• 3.2 Crankshaft dimensions
  89
• 3.3 Measuring axial clearance of crankshaft
  90
• 3.4 Measuring radial clearance of crankshaft
  91
• 3.5 Renewing needle bearing in crankshaft
  91
• 4 Auxiliary drive
  94
• 4.1 Assembly overview - ancillary drive
  94
• 4.2 Retrofitting preparation for ancillary drive
  94
• 5 Pistons and conrods
  97
• 5.1 Assembly overview - pistons and conrods
  97
• 5.2 Checking pistons and cylinder bores
  99
• 5.3 Measuring piston projection at TDC
  101
• 5.4 Checking radial clearance of conrods
  103
• 5.5 Bearing shells - installation position
  103
• 5.6 Separating new conrod
  104
• Cylinder head, valve gear
  106
• 1 Cylinder head
  106
• 1.1 Assembly overview - cylinder head
  106
• 1.2 Assembly overview - cylinder head cover
  110
• 1.3 Removing and installing cylinder head
  114
• 1.4 Removing and installing cylinder head cover
  124
• 1.5 Removing and installing injector seals
  131
• 1.6 Removing and installing vacuum pump
  133
• 1.7 Checking compression
  134
• 2 Toothed belt drive
  136
• 2.1 Assembly overview - toothed belt
  136
• 2.2 Removing and installing toothed belt
  138
• 3 Fully enclosing toothed belt guard
  150
• 3.1 Assembly overview - fully enclosing toothed belt guard
  150
• 3.2 Removing and installing front toothed belt guard (fully enclosing)
  153
• 3.3 Removing and installing lower toothed belt guard (fully enclosed)
  156
• 3.4 Removing and installing rear toothed belt guard (fully enclosing)
  157
• 4 Air supply for toothed belt drive
  162
• 4.1 Assembly overview - air supply for toothed belt drive
  162
• 4.2 Removing and installing blower of air supply for toothed belt drive
  162
• 4.3 Removing and installing air filter housing of air supply for toothed belt drive
  163
• 4.4 Removing and installing console of air supply for toothed belt drive
  164
• 5 Valve gear
  165
• 5.1 Assembly overview - valve gear
  165
• 5.2 Measuring axial play of camshaft
  168
• 5.3 Measuring radial play of camshaft
  169
• 5.4 Removing and installing camshaft
  169
• 5.5 Removing and installing camshaft oil seal
  179
• 5.6 Checking hydraulic compensation elements
  185
• 5.7 Removing and installing valve stem seals
  185
• 6 Inlet and exhaust valves
  191
• 6.1 Reworking valve seats
  191
• 6.2 Checking valve guides
  191
• 6.3 Valve dimensions
  192
• Lubrication
  193
• 1 Sump, oil pump
  193
• 1.1 Assembly overview - sump/oil pump
  193
• 1.2 Removing and installing oil sump
  195
• 1.3 Removing and installing oil pump
  203
• 1.4 Removing and installing oil level and oil temperature sender G266
  205
• 1.5 Removing and installing dipstick tube
  206
• 2 Engine oil cooler
  208
• 2.1 Checking engine oil cooler for leaks
  208
• 3 Oil filter, oil pressure switch
  211
• 3.1 Assembly overview - oil filter
  211
• 3.2 Removing and installing oil filter housing
  213
• 3.3 Removing and installing oil pressure switch F1
  216
• 3.4 Checking oil pressure and oil pressure switch
  217
• 4 Oil circuit
  221
• 4.1 Removing and installing oil supply line, bi-turbo
  221
• 4.2 Removing and installing oil pressure line for turbocharger, mono-turbo
  224
• 5 Balancer shaft module
  227
• 5.1 Assembly overview - balancer shaft module
  227
• 5.2 Removing and installing balance shaft module
  231
• Cooling
  240
• 1 Cooling system/coolant
  240
• 1.1 Connection diagram - coolant hoses
  240
• 1.2 Assembly overview - coolant hoses
  245
• 1.3 Checking cooling system for leaks
  247
• 1.4 Draining and adding coolant
  249
• 2 Coolant pump, regulation of cooling system
  259
• 2.1 Assembly overview - coolant pump, thermostat
  259
• 2.2 Assembly overview - electric coolant pump
  260
• 2.3 Removing and installing coolant pump
  262
• 2.4 Removing and installing 4/2-way valve with thermostat
  266
• 2.5 Removing and installing coolant temperature sender G62
  272
• 2.6 Removing and installing radiator outlet coolant temperature sender G83
  273
• 2.7 Removing and installing electric coolant pump
  275
• 2.8 Removing and installing Y-thermostat
  280
• 3 Radiator, radiator fan
  283
• 3.1 Assembly overview - radiator/radiator fan
  283
• 3.2 Assembly overview – radiator cowl and radiator fan
  285
• 3.3 Removing and installing radiator
  285
• 3.4 Removing and installing radiator cowl with radiator fan
  289
• Turbocharging/supercharging
  292
• 1 Turbocharger
  292
• 1.1 Assembly overview - turbocharger
  292
• 1.2 Removing and installing turbocharger
  301
• 1.3 Renewing seal between bi-turbo turbine housings
  311
• 1.4 Checking vacuum unit for turbocharger, bi-turbo
  315
• 1.5 Checking regulating flap potentiometer G584
  317
• 1.6 Removing and installing charge pressure sender 2 G447
  320
• 1.7 Removing and installing vacuum unit for turbocharger
  322
• 1.8 Removing and installing charge pressure control solenoid valve N75
  337
• 2 Charge air system
  339
• 2.1 Assembly overview - charge air system
  339
• 2.2 Removing and installing charge air cooler
  340
• 2.4 Removing and installing exhaust gas flap valve N220
  342
• 2.5 Checking charge air system for leaks
  343
• Mixture preparation - injection
  347
• 1 Injection system
  347
• 1.1 Schematic overview - fuel system
  347
• 1.2 Overview of fitting locations - injection system
  348
• 1.3 Assembly overview - fuel system
  357
• 1.4 Checking fuel system for leaks
  363
• 1.5 Filling/bleeding fuel system
  364
• 2 Vacuum system
  365
• 2.1 Connection diagram – vacuum system
  365
• 2.2 Checking vacuum system
  371
• 3 Injectors/high-pressure accumulator (rail)
  381
• 3.1 Overview of injectors
  381
• 3.2 Adapting correction values for injectors
  381
• 3.3 Removing and installing injectors
  382
• 3.4 Removing and installing high-pressure lines
  393
• 3.5 Removing and installing fuel rail
  396
• 3.6 Checking return flow rate of injectors with engine running
  400
• 4 Air filter
  404
• 4.1 Assembly overview - air filter housing
  404
• 4.2 Removing and installing air filter housing
  407
• 5 Intake manifold
  409
• 5.1 Assembly overview – intake manifold
  409
• 5.2 Removing and installing intake manifold
  410
• 5.3 Removing and installing throttle valve module GX3
  414
• 6 Senders and sensors
  416
• 6.1 Removing and installing air mass meter G70
  416
• 6.2 Removing and installing exhaust pressure sensor 1 G450
  417
• 6.3 Removing and installing fuel pressure regulating valve N276
  419
• 6.4 Checking fuel pressure regulating valve N276
  422
• 6.5 Removing and installing fuel pressure sender G247
  424
• 7 Engine control unit
  428
• 7.1 Removing and installing engine control unit J623
  428
• 8 High-pressure pump
  429
• 8.1 Assembly overview - high-pressure pump
  429
• 8.2 Removing and installing high-pressure pump
  430
• 8.3 Checking high-pressure pump
  433
• Exhaust system
  437
• 1 Exhaust pipes and silencers
  437
• 1.1 Assembly overview – silencers
  437
• 1.2 Checking exhaust system for leaks
  440
• 1.3 Aligning exhaust system free of stress
  440
• 2 Emission control
  442
• 2.1 Assembly overview – emission control
  442
• 2.2 Removing and installing particulate filter
  446
• 2.3 Removing and installing catalytic converter
  453
• 3 Exhaust gas recirculation
  457
• 3.1 Assembly overview – exhaust gas recirculation
  457
• 3.2 Removing and installing exhaust gas recirculation cooler
  459
• 3.3 Removing and installing exhaust gas recirculation valve 1 GX5
  468
• 3.5 Pressure loss test for exhaust gas recirculation cooler
  470
• Glow plug system
  474
• 1 Glow plug system
  474
• 1.1 Assembly overview – glow plug system
  474
• 1.2 Checking glow plug system
  476
• 1.3 Removing and installing glow plug
  476
• 1.4 Removing and installing engine speed sender G28
  479
• 1.5 Removing and installing Hall sender G40
  481