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

Chapter overview

• Technical data
  1
• 1 Identification
  1
• 1.1 Engine number/engine data
  1
• 2 Safety information
  3
• 2.1 Safety precautions when working on fuel system
  3
• 2.2 Safety measures when working on vehicles with a start/stop system
  4
• 2.4 Safety precautions when working on the cooling system
  5
• 3 Repair instructions
  6
• 3.1 Rules for cleanliness
  6
• 3.2 Foreign objects in engine
  7
• 3.3 Checking vacuum system
  7
• Removing and installing engine
  8
• 1 Removing and installing engine
  8
• 1.1 Removing engine
  8
• 1.2 Separating engine and gearbox
  22
• 1.3 Securing engine on engine and gearbox support
  26
• 1.4 Installing engine
  28
• 2 Assembly mountings
  32
• 2.1 Assembly overview - assembly mountings
  32
• 2.2 Removing and installing engine mounting
  34
• 2.3 Supporting engine in installation position
  43
• 2.4 Adjusting assembly mountings
  52
• 2.5 Checking adjustment of assembly mountings
  53
• 3 Engine cover panel
  55
• 3.1 Removing and installing engine cover
  55
• Crankshaft group
  57
• 1 Cylinder block (pulley end)
  57
• 1.1 Assembly overview - poly V-belt drive
  57
• 1.2 Removing and installing poly-V belt
  61
• 1.3 Removing and installing tensioner for poly V-belt
  66
• 1.4 Removing and installing vibration damper
  67
• 1.5 Removing and installing bracket for ancillaries
  69
• 1.6 Removing and installing engine bracket
  71
• 1.7 Assembly overview - sealing flange, belt pulley end
  74
• 1.8 Renewing crankshaft oil seal - belt pulley end
  76
• 1.9 Removing and installing sealing flange on pulley end
  78
• 2 Cylinder block, gearbox end
  83
• 2.1 Assembly overview - cylinder block, gearbox end
  83
• 2.2 Removing and installing flywheel
  84
• 2.3 Removing and installing sealing flange on gearbox side
  86
• 3 Crankshaft
  100
• 3.1 Assembly overview - crankshaft
  100
• 3.2 Crankshaft dimensions
  101
• 3.3 Renewing needle bearing in crankshaft
  101
• 3.4 Measuring axial clearance of crankshaft
  103
• 3.5 Measuring radial clearance of crankshaft
  104
• 4 Pistons and conrods
  105
• 4.1 Assembly overview - pistons and conrods
  105
• 4.2 Measuring piston projection at TDC
  107
• 4.3 Checking pistons and cylinder bores
  109
• 4.4 Separating new conrod
  112
• 4.5 Checking radial clearance of conrods
  113
• Cylinder head, valve gear
  114
• 1 Cylinder head
  114
• 1.1 Assembly overview - cylinder head
  114
• 1.2 Assembly overview - cylinder head cover
  118
• 1.3 Removing and installing cylinder head
  120
• 1.4 Removing and installing cylinder head cover
  135
• 1.5 Removing and installing injector seals
  137
• 1.6 Removing and installing vacuum pump
  138
• 1.7 Checking compression
  140
• 2 Toothed belt drive
  143
• 2.1 Assembly overview - toothed belt
  143
• 2.2 Removing and installing toothed belt
  145
• 3 Valve gear
  157
• 3.1 Assembly overview - valve gear
  157
• 3.2 Measuring axial play of camshaft
  159
• 3.3 Measuring radial play of camshaft
  160
• 3.4 Removing and installing camshaft oil seal
  161
• 3.5 Removing and installing camshaft
  169
• 3.6 Checking hydraulic compensation elements
  178
• 3.7 Removing and installing valve stem seal
  179
• 4 Inlet and exhaust valves
  188
• 4.1 Reworking valve seats
  188
• 4.2 Checking valve guides
  188
• 4.3 Checking valves
  189
• 4.4 Valve dimensions
  189
• Lubrication
  190
• 1 Engine oil:
  190
• 1.1 Oil capacities
  190
• 1.2 Checking engine oil level
  190
• 2 Sump, oil pump
  192
• 2.1 Assembly overview - sump/oil pump
  192
• 2.2 Removing and installing oil sump
  195
• 2.3 Removing and installing oil pump
  200
• 2.4 Removing and installing oil level and oil temperature sender G 266
  201
• 3 Oil filter, oil pressure switch
  203
• 3.1 Assembly overview - oil filter housing, oil pressure switch
  203
• 3.2 Removing and installing oil pressure switch F1
  205
• 3.3 Checking oil pressure
  206
• 3.4 Checking oil pressure and oil pressure switch
  207
• 3.5 Removing and installing oil filter housing
  209
• 4 Oil circuit
  214
• 4.1 Assembly overview - oil circuit
  214
• 4.2 Removing and installing oil supply line to turbocharger
  214
• 4.3 Removing and installing oil return line for turbocharger
  216
• Cooling
  223
• 1 Cooling system/coolant
  223
• 1.1 Coolant hose connection diagram
  223
• 1.2 Overview of fitting locations – cooling system
  225
• 1.3 Engine preheater
  229
• 1.4 Checking cooling system for leaks
  231
• 1.5 Draining and adding coolant
  233
• 2 Coolant pump, regulation of cooling system
  239
• 2.1 Assembly overview - coolant pump, thermostat
  239
• 2.2 Coolant circulation pump 2 V178
  239
• 2.3 Removing and installing coolant pump
  243
• 2.4 Removing and installing 4/2-way valve with thermostat
  245
• 2.5 Removing and installing coolant temperature sender
  251
• 3 Coolant pipes
  256
• 3.1 Assembly overview - coolant pipes
  256
• 3.2 Removing and installing coolant pipes
  258
• 4 Radiator, radiator fan
  268
• 4.1 Assembly overview - radiator/radiator fan
  268
• 4.2 Removing and installing radiator
  269
• 4.3 Removing and installing radiator cowl with radiator fan
  272
• 4.4 Removing and installing radiator fan
  273
• Turbocharging/supercharging
  274
• 1 Turbocharger
  274
• 1.1 Assembly overview - turbocharger
  274
• 1.2 Removing and installing turbocharger
  278
• 1.3 Renewing vacuum unit for turbocharger
  282
• 2 Charge air system
  292
• 2.1 Assembly overview - charge air system
  292
• 2.2 Assembly overview - charge-air hose connections
  294
• 2.3 Removing and installing charge air cooler
  296
• 2.5 Checking charge air system for leaks
  300
• Mixture preparation - injection
  305
• 1 Injection system
  305
• 1.1 Schematic overview - fuel system
  305
• 1.2 Filling/bleeding fuel system
  307
• 1.3 Checking for leaks in the fuel system
  308
• 2 Vacuum system
  309
• 2.1 Connection diagram - vacuum system
  309
• 2.2 Checking vacuum system
  310
• 3 Injectors/high-pressure accumulator (rail)
  313
• 3.1 Assembly overview - injectors
  313
• 3.2 Removing and installing injectors
  317
• 3.3 Installing high-pressure lines
  322
• 4 High-pressure pump
  325
• 4.1 Assembly overview - high-pressure pump
  325
• 4.2 Removing and installing high-pressure pump
  327
• 5 Senders and sensors
  332
• 5.1 Checking fuel pressure regulating valve N276
  332
• 5.2 Check pressure retention valve in fuel return line
  333
• 5.3 Removing and installing fuel pressure regulating valve N276
  334
• 5.4 Removing and installing fuel pressure sender G247
  336
• 5.5 Removing and installing air mass meter G70
  338
• 5.6 Removing and installing differential pressure sensor
  340
• 6 Intake manifold
  342
• 6.1 Assembly overview – intake manifold
  342
• 6.2 Removing and installing intake manifold
  343
• 6.3 Removing and installing throttle valve module
  348
• 7 Lambda probe
  351
• 7.1 Removing and installing Lambda probe G39
  351
• 8 Air filter
  353
• 8.1 Assembly overview - air filter
  353
• 8.2 Removing and installing air filter housing
  355
• 8.3 Removing and installing air filter element
  356
• 8.4 Checking changeover flap for intake air preheating
  358
• 8.5 Removing and installing changeover flap for intake air preheating
  360
• 9 Engine control unit
  363
• 9.1 Removing and installing engine control unit
  363
• 9.2 Removing and installing engine control unit with protective housing
  364
• Exhaust system
  367
• 1 Exhaust pipes and silencers
  367
• 1.1 Assembly overview – silencers
  367
• 1.2 Separating exhaust pipes/silencers, saloon
  370
• 1.3 Removing and installing rear silencer, Cabriolet
  371
• 1.4 Aligning exhaust system free of stress
  372
• 1.5 Installation position of clamp
  373
• 2 Emission control
  375
• 2.1 Assembly overview – emission control
  375
• 2.2 Removing and installing particulate filter with NOx storage catalytic converter
  386
• 3 Exhaust gas temperature regulation
  394
• 3.1 Removing and installing parts of exhaust gas temperature regulation
  394
• 4 Exhaust gas recirculation
  405
• 4.1 Assembly overview – exhaust gas recirculation
  405
• 4.2 Removing and installing exhaust gas recirculation filter
  407
• 4.3 Removing and installing exhaust gas recirculation cooler
  409
• 4.4 Checking changeover for exhaust gas recirculation cooler
  412
• Glow plug system
  414
• 1 Glow plug system
  414
• 1.1 Removing and installing glow plug
  414
• 1.2 Removing and installing connectors for glow pin plugs
  417
• 1.3 Removing and installing automatic glow period control unit J179
  420
• 1.4 Removing and installing Hall sender G40
  421
• 1.5 Removing and installing engine speed sender G28
  424