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 precautions when working on injection system
  2
• 1.4 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 on the lubrication system
  7
• 3.2 General notes on fuel system
  7
• 3.3 Instructions for working on fuel system
  8
• 3.4 Rules for cleanliness when working on fuel supply system
  10
• 3.5 Rules for cleanliness during work on fuel system
  10
• 3.6 Rules for cleanliness when working on injection system
  11
• 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
  30
• 1.3 Installing engine
  32
• 1.4 Modifying engine bracket T10229
  35
• 1.5 Converting adapter 10 - 222 A /23 with adapter 10 - 222 A /23-1
  36
• 2 Assembly mountings
  38
• 2.1 Assembly overview - assembly mountings
  38
• 2.2 Supporting engine in installation position
  40
• 2.3 Removing and installing engine mounting
  41
• 2.4 Removing and installing engine mounting
  47
• Crankshaft group
  51
• 1 Cylinder block (pulley end)
  51
• 1.1 Assembly overview - cylinder block (pulley end)
  51
• 1.2 Assembly overview - sealing flange, belt pulley end
  53
• 1.3 Assembly overview - poly V-belt drive
  55
• 1.4 Removing and installing poly-V belt
  61
• 1.5 Removing and installing tensioner for poly V-belt
  63
• 1.6 Removing and installing bracket for ancillaries
  64
• 1.7 Removing and installing vibration damper
  67
• 1.8 Renewing crankshaft oil seal - belt pulley end
  68
• 1.9 Removing and installing sealing flange on pulley end
  71
• 2 Cylinder block, gearbox end
  77
• 2.1 Assembly overview - cylinder block, gearbox end
  77
• 2.2 Removing and installing flywheel
  78
• 2.3 Removing and installing sealing flange on gearbox side
  80
• 3 Crankshaft
  92
• 3.1 Assembly overview - crankshaft
  92
• 3.2 Crankshaft dimensions
  93
• 3.3 Allocation of main bearing shells
  94
• 3.4 Measuring axial clearance of crankshaft
  94
• 3.5 Measuring radial clearance of crankshaft
  95
• 3.6 Renewing needle bearing in crankshaft
  96
• 3.7 Renewing spur gear for crankshaft
  98
• 4 Pistons and conrods
  102
• 4.1 Assembly overview - pistons and conrods
  102
• 4.2 Removing and installing pistons
  105
• 4.3 Separating new conrod
  106
• 4.4 Checking pistons and cylinder bores
  107
• 4.5 Checking radial clearance of conrods
  108
• 4.6 Measuring piston projection at TDC
  109
• 4.7 Removing and installing oil spray jets
  111
• Cylinder head, valve gear
  113
• 1 Cylinder head
  113
• 1.1 Assembly overview - cylinder head
  113
• 1.2 Assembly overview - cylinder head cover
  117
• 1.3 Removing and installing cylinder head
  122
• 1.4 Removing and installing cylinder head cover
  134
• 1.5 Removing and installing injector seals
  141
• 1.6 Removing and installing vacuum pump
  145
• 1.7 Checking compression
  149
• 2 Fully enclosing toothed belt guard
  151
• 2.1 Assembly overview - fully enclosing toothed belt guard
  151
• 2.2 Removing and installing upper toothed belt guard (fully enclosing)
  153
• 2.3 Removing and installing lower toothed belt guard (fully enclosed)
  154
• 2.4 Removing and installing rear toothed belt guard (fully enclosing)
  156
• 3 Toothed belt drive
  160
• 3.1 Assembly overview - toothed belt
  160
• 3.2 Removing and installing toothed belt
  162
• 4 Valve gear
  180
• 4.1 Assembly overview - valve gear
  180
• 4.2 Measuring axial play of camshaft
  183
• 4.3 Measuring radial play of camshaft
  184
• 4.4 Removing and installing camshaft oil seal
  184
• 4.5 Removing and installing camshaft
  187
• 4.6 Checking hydraulic compensation elements
  196
• 4.7 Removing and installing valve stem seals
  197
• 5 Inlet and exhaust valves
  202
• 5.1 Reworking valve seats
  202
• 5.2 Checking valve guides
  202
• 5.3 Valve dimensions
  203
• Lubrication
  204
• 1 Sump, oil pump
  204
• 1.1 Assembly overview - sump/oil pump
  204
• 1.2 Removing and installing sump
  210
• 1.3 Removing and installing oil pump
  215
• 1.4 Engine oil:
  217
• 1.5 Removing and installing oil level and oil temperature sender G266
  218
• 2 Engine oil cooler
  220
• 2.1 Assembly overview - engine oil cooler
  220
• 2.2 Removing and installing engine oil cooler
  222
• 2.3 Checking engine oil cooler for leaks
  226
• 3 Oil filter, oil pressure switch
  229
• 3.1 Assembly overview - oil filter housing
  229
• 3.2 Removing and installing oil pressure switch F1
  229
• 3.3 Checking oil pressure
  230
• 3.4 Removing and installing oil filter housing, mono-turbo
  232
• 3.5 Measuring oil consumption
  235
• 4 Balancer shaft module
  237
• 4.1 Removing and installing balance shaft module
  237
• Cooling
  245
• 1 Cooling system/coolant
  245
• 1.1 Draining and adding coolant
  245
• 1.2 Checking cooling system for leaks
  254
• 1.3 Assembly overview - coolant hoses
  256
• 1.4 Connection diagram for coolant hoses - vehicles with basic equipment
  258
• 1.5 Connection diagram for coolant hoses - vehicles with additional heat exchanger
  260
• 1.6 Connection diagram for coolant hoses - vehicles with auxiliary heater
  265
• 2 Coolant pump, regulation of cooling system
  287
• 2.1 Assembly overview - coolant pump and ball thermostat (4/2-way valve)
  287
• 2.2 Assembly overview - Continued coolant circulation pump V51
  288
• 2.3 Removing and installing coolant pump
  288
• 2.4 Removing and installing continued coolant circulation pump V51
  291
• 2.5 Removing and installing 4/2-way valve with thermostat
  293
• 2.6 Removing and installing Y-thermostat
  298
• 2.7 Removing and installing coolant temperature sender G62
  299
• 2.8 Removing and installing radiator outlet coolant temperature sender G83
  302
• 3 Radiator, radiator fan
  307
• 3.1 Assembly overview - radiator/radiator fan
  307
• 3.2 Assembly overview – radiator cowl and radiator fan
  309
• 3.3 Removing and installing radiator
  309
• 3.4 Removing and installing radiator cowl with radiator fan V7
  317
• Fuel supply system
  319
• 1 Procedure in event of misfuelling
  319
• 1.1 Procedure in event of misfuelling
  319
• 2 Fuel
  323
• 2.1 Assembly overview - fuel tank
  323
• 2.2 Removing and installing fuel tank
  325
• 3 Fuel delivery unit, fuel gauge sender
  330
• 3.1 Removing and installing fuel delivery unit
  330
• 3.2 Removing and installing fuel gauge sender G
  331
• 4 Fuel pump
  332
• 4.1 Assembly overview - supplementary fuel pump V393
  332
• 4.2 Removing and installing supplementary fuel pump V393
  334
• 4.3 Checking supplementary fuel pump V393
  337
• 4.4 Checking delivery pressure of fuel system pressurisation pump G6
  339
• 4.5 Checking fuel delivery rate of fuel system pressurisation pump G6
  340
• 4.6 Checking voltage supply of fuel system pressurisation pump G6
  342
• 4.7 Checking current draw of fuel system pressurisation pump G6
  343
• 5 Accelerator pedal
  346
• 5.1 Function
  346
• 5.2 Assembly overview - accelerator mechanism
  346
• Turbocharging/supercharging
  348
• 1 Turbocharger
  348
• 1.1 Assembly overview - turbocharger
  348
• 1.2 Assembly overview – connecting pipes (bi-turbo)
  358
• 1.3 Removing and installing turbocharger
  360
• 1.4 Removing and installing exhaust manifold gasket (bi-turbo)
  395
• 1.5 Removing and installing compressor housing and turbine housing (bi-turbo)
  405
• 1.6 Checking vacuum unit for turbocharger
  408
• 1.7 Renewing vacuum unit for turbocharger
  417
• 1.8 Removing and installing connecting pipes (bi-turbo)
  431
• 2 Charge air system
  439
• 2.1 Assembly overview - charge air system
  439
• 2.2 Assembly overview - charge-air hose connections
  443
• 2.3 Removing and installing charge air cooler
  447
• 2.5 Removing and installing exhaust gas flap valve N220
  453
• 2.7 Removing and installing charge pressure control solenoid valve N75
  454
• 2.8 Checking charge air system for leaks
  456
• 2.9 Removing and installing charge pressure sender 2 G447
  460
• Mixture preparation - injection
  462
• 1 Injection system
  462
• 1.1 Overview of fitting locations - injection system
  462
• 1.2 Schematic overview - fuel system
  472
• 1.3 Assembly overview - fuel system
  474
• 1.4 Checking fuel system for leaks
  480
• 2 Vacuum system
  481
• 2.1 Connection diagram - vacuum system
  481
• 2.2 Testing vacuum system for leaks, bi-turbo
  485
• 2.3 Testing vacuum system for leaks, mono-turbo
  494
• 2.4 Checking vacuum system for leaks, “four-wheel drive”
  501
• 3 Injectors/high-pressure accumulator (rail)
  509
• 3.1 Removing and installing fuel rail
  509
• 3.2 Removing and installing high-pressure lines
  513
• 3.3 Removing and installing injectors
  520
• 3.4 Testing injectors
  526
• 3.5 Testing jammed-open injectors
  534
• 3.6 Check pressure retention valve in fuel return line
  536
• 3.7 Checking low pressure fuel system
  539
• 3.8 Checking fuel pump delivery rate
  541
• 4 Air filter
  543
• 4.1 Assembly overview - air filter housing
  543
• 4.2 Removing and installing air filter housing
  546
• 5 Intake manifold
  549
• 5.1 Assembly overview – intake manifold
  549
• 5.2 Removing and installing intake manifold
  549
• 5.3 Removing and installing throttle valve module GX3
  554
• 6 Senders and sensors
  556
• 6.1 Removing and installing air mass meter G70
  556
• 6.2 Removing and installing fuel pressure regulating valve N276
  557
• 6.3 Checking fuel pressure regulating valve N276
  560
• 6.4 Removing and installing fuel pressure sender G247
  562
• 6.5 Removing and installing exhaust gas pressure sensor 1 G450
  564
• 7 Engine control unit
  568
• 7.1 Removing and installing engine control unit J623
  568
• 8 High-pressure pump
  570
• 8.1 Removing and installing high-pressure pump
  570
• 8.2 Checking high-pressure pump
  574
• Exhaust system
  578
• 1 Exhaust pipes and silencers
  578
• 1.1 Assembly overview – silencers
  578
• 1.2 Removing and installing front exhaust pipe
  582
• 1.3 Separating exhaust pipes from silencers
  584
• 1.4 Checking exhaust system for leaks
  585
• 1.5 Aligning exhaust system free of stress
  586
• 1.6 Installation position of clamp
  587
• 2 Emission control
  588
• 2.1 Assembly overview - particulate filter
  588
• 2.2 Assembly overview - catalytic converter, four-wheel drive vehicles
  593
• 2.3 Removing and installing particulate filter
  595
• 2.4 Removing and installing catalytic converter, four-wheel drive vehicles
  602
• 3 Exhaust gas recirculation
  605
• 3.1 Assembly overview – exhaust gas recirculation
  605
• 3.2 Removing and installing exhaust gas recirculation cooler
  608
• 3.3 Removing and installing exhaust gas recirculation valve 1 GX5
  620
• 3.4 Pressure loss test for exhaust gas recirculation cooler
  621
• Glow plug system
  625
• 1 Glow plug system
  625
• 1.1 Checking glow plug system
  625
• 1.2 Removing and installing glow plug
  625
• 1.3 Checking glow plug
  628
• 1.4 Optical characteristics of glow plugs
  629
• 1.5 Removing and installing engine speed sender G28
  629
• 1.6 Removing and installing Hall sender G40
  631