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

Chapter overview

• Technical data
  1
• 1 Identification
  1
• 1.1 Engine number/engine data
  1
• 2 General information
  3
• 2.1 Numbering of cylinders
  3
• 3 Safety information
  4
• 3.1 Safety precautions when working on fuel system
  4
• 3.2 Safety measures when working on vehicles with a start/stop system
  5
• 3.4 Safety precautions when working on the cooling system
  6
• 4 Repair instructions
  7
• 4.1 Rules for cleanliness
  7
• 4.2 Foreign objects in engine
  7
• 4.3 Checking vacuum system
  8
• Removing and installing engine
  9
• 1 Removing and installing engine
  9
• 1.1 Removing engine
  9
• 1.2 Separating engine and gearbox
  23
• 1.3 Securing engine on engine and gearbox support
  28
• 1.4 Installing engine
  30
• 2 Assembly mountings
  34
• 2.1 Assembly overview - assembly mountings
  34
• 2.2 Removing and installing engine mounting
  36
• 2.3 Supporting engine in installation position
  45
• 2.4 Adjusting assembly mountings
  54
• 2.5 Checking adjustment of assembly mountings
  56
• 3 Engine cover panel
  58
• 3.1 Removing and installing engine cover
  58
• Crankshaft group
  60
• 1 Cylinder block (pulley end)
  60
• 1.1 Assembly overview - poly V-belt drive
  60
• 1.2 Removing and installing poly-V belt
  64
• 1.3 Removing and installing tensioner for poly V-belt
  69
• 1.4 Removing and installing vibration damper
  71
• 1.5 Removing and installing bracket for ancillaries
  72
• 1.6 Removing and installing engine bracket
  74
• 1.7 Assembly overview - sealing flange, belt pulley end
  77
• 1.8 Renewing crankshaft oil seal - belt pulley end
  79
• 1.9 Removing and installing sealing flange on pulley end
  81
• 2 Cylinder block, gearbox end
  86
• 2.1 Assembly overview - cylinder block, gearbox end
  86
• 2.2 Removing and installing flywheel
  87
• 2.3 Removing and installing sealing flange on gearbox side
  89
• 3 Crankshaft
  103
• 3.1 Assembly overview - crankshaft
  103
• 3.2 Crankshaft dimensions
  104
• 3.3 Renewing needle bearing in crankshaft
  104
• 3.4 Measuring axial clearance of crankshaft
  106
• 3.5 Measuring radial clearance of crankshaft
  107
• 4 Pistons and conrods
  108
• 4.1 Assembly overview - pistons and conrods
  108
• 4.2 Measuring piston projection at TDC
  110
• 4.3 Checking pistons and cylinder bores
  112
• 4.4 Separating new conrod
  115
• 4.5 Checking radial clearance of conrods
  116
• Cylinder head, valve gear
  117
• 1 Cylinder head
  117
• 1.1 Assembly overview - cylinder head
  117
• 1.2 Assembly overview - cylinder head cover
  121
• 1.3 Removing and installing cylinder head
  123
• 1.4 Removing and installing cylinder head cover
  139
• 1.5 Removing and installing vacuum pump
  142
• 1.6 Checking compression
  144
• 2 Toothed belt drive
  147
• 2.1 Assembly overview - toothed belt
  147
• 2.2 Removing and installing toothed belt
  149
• 3 Valve gear
  173
• 3.1 Assembly overview - valve gear
  173
• 3.2 Measuring axial play of camshaft
  175
• 3.3 Measuring radial play of camshaft
  176
• 3.4 Removing and installing camshaft oil seal
  177
• 3.5 Removing and installing camshaft
  185
• 3.6 Checking hydraulic compensation elements
  194
• 3.7 Removing and installing valve stem seal
  195
• 4 Inlet and exhaust valves
  204
• 4.1 Reworking valve seats
  204
• 4.2 Checking valve guides
  204
• 4.3 Checking valves
  205
• 4.4 Valve dimensions
  205
• Lubrication
  206
• 1 Sump, oil pump
  206
• 1.1 Assembly overview - sump/oil pump
  206
• 1.2 Removing and installing oil sump
  212
• 1.3 Removing and installing oil pump
  217
• 1.4 Removing and installing oil level and oil temperature sender G 266
  219
• 2 Engine oil cooler
  221
• 2.1 Assembly overview - engine oil cooler
  221
• 2.2 Removing and installing engine oil cooler
  221
• 3 Oil filter, oil pressure switch
  225
• 3.1 Assembly overview - oil filter housing, oil pressure switch
  225
• 3.2 Removing and installing oil pressure switch F1
  226
• 3.3 Checking oil pressure
  227
• 3.4 Checking oil pressure and oil pressure switch
  228
• 3.5 Removing and installing oil filter housing
  229
• 4 Oil circuit
  235
• 4.1 Assembly overview - oil circuit
  235
• 4.2 Removing and installing oil return line for turbocharger
  235
• 5 Balancer shaft module
  241
• 5.1 Removing and installing balance shaft module
  241
• Cooling
  251
• 1 Cooling system/coolant
  251
• 1.1 Coolant hose connection diagram
  251
• 1.2 Checking cooling system for leaks
  253
• 1.3 Draining and adding coolant
  254
• 2 Coolant pump, regulation of cooling system
  261
• 2.1 Assembly overview - coolant pump, thermostat
  261
• 2.2 Coolant circulation pump 2 V178
  261
• 2.3 Removing and installing coolant pump
  265
• 2.4 Removing and installing 4/2-way valve with thermostat
  267
• 2.5 Removing and installing coolant temperature sender
  273
• 3 Coolant pipes
  278
• 3.1 Assembly overview - coolant pipes
  278
• 3.2 Removing and installing coolant pipes
  280
• 4 Radiator, radiator fan
  293
• 4.1 Assembly overview - radiator, radiator fan
  293
• 4.2 Removing and installing radiator
  293
• 4.3 Removing and installing radiator cowl with radiator fan
  296
• 4.4 Removing and installing radiator fan
  297
• Turbocharging/supercharging
  298
• 1 Turbocharger
  298
• 1.1 Assembly overview - turbocharger
  298
• 1.2 Removing and installing turbocharger
  300
• 1.3 Renewing vacuum unit for turbocharger
  307
• 2 Charge air system
  314
• 2.1 Assembly overview - charge air system
  314
• 2.2 Assembly overview - charge-air hose connections
  316
• 2.3 Removing and installing charge air cooler
  318
• 2.5 Checking charge air system for leaks
  321
• Mixture preparation - injection
  325
• 1 Injection system
  325
• 1.1 Schematic overview - fuel system
  325
• 1.2 Filling/bleeding fuel system
  327
• 1.3 Checking fuel system for leaks
  328
• 2 Vacuum system
  329
• 2.1 Connection diagram - vacuum system
  329
• 2.2 Checking vacuum system
  330
• 3 Injectors/high-pressure accumulator (rail)
  333
• 3.1 Assembly overview - injectors
  333
• 3.2 Adapting correction values for injectors
  336
• 3.3 Testing jammed-open injectors
  337
• 3.4 Removing and installing injectors
  339
• 3.5 Removing and installing fuel rail
  343
• 3.6 Removing and installing high-pressure lines
  347
• 4 High-pressure pump
  352
• 4.1 Assembly overview - high-pressure pump
  352
• 4.2 Removing and installing high-pressure pump
  354
• 5 Senders and sensors
  360
• 5.1 Checking fuel pressure regulating valve
  360
• 5.2 Removing and installing fuel pressure regulating valve
  361
• 5.3 Removing and installing fuel pressure sender
  363
• 5.4 Removing and installing air mass meter
  366
• 5.5 Removing and installing differential pressure sensor
  367
• 6 Intake manifold
  369
• 6.1 Assembly overview – intake manifold
  369
• 6.2 Removing and installing intake manifold
  370
• 6.3 Removing and installing throttle valve module
  375
• 7 Lambda probe
  377
• 7.1 Removing and installing Lambda probe G39 with Lambda probe heater Z19
  377
• 8 Air filter
  379
• 8.1 Assembly overview - air filter housing
  379
• 8.2 Removing and installing air filter housing
  381
• 8.3 Checking changeover flap for intake air preheating
  383
• 8.4 Removing and installing changeover flap for intake air preheating
  384
• 9 Engine control unit
  387
• 9.1 Removing and installing engine control unit
  387
• 9.2 Removing and installing engine control unit with protective housing
  388
• Exhaust system
  391
• 1 Exhaust pipes and silencers
  391
• 1.1 Assembly overview – silencers
  391
• 1.2 Separating exhaust pipes from silencers
  392
• 1.3 Aligning exhaust system free of stress
  394
• 1.4 Installation position of clamp
  395
• 2 Emission control
  397
• 2.1 Assembly overview – emission control
  397
• 2.2 Removing and installing particulate filter
  400
• 3 Exhaust gas temperature regulation
  409
• 3.1 Removing and installing parts of exhaust gas temperature regulation
  409
• 4 Exhaust gas recirculation
  416
• 4.1 Assembly overview – exhaust gas recirculation
  416
• 4.2 Removing and installing exhaust gas recirculation cooler
  417
• 4.3 Checking changeover for exhaust gas recirculation cooler
  420
• 4.4 Checking exhaust gas recirculation cooler for leaks
  421
• 4.5 Cleaning exhaust gas recirculation system
  426
• Glow plug system
  434
• 1 Glow plug system
  434
• 1.1 Removing and installing glow plug
  434
• 1.2 Removing and installing automatic glow period control unit J179
  436
• 1.3 Removing and installing Hall sender G40
  438
• 1.4 Removing and installing engine speed sender G28
  439