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 Safety information
  2
• 2.1 Safety regulations for working on fuel supply
  2
• 2.2 Safety precautions when working on fuel system
  2
• 2.3 Safety precautions when working on the cooling system
  3
• 3 Repair instructions
  5
• 3.1 Rules for cleanliness
  5
• 3.2 General repair instructions
  6
• Removing and installing engine
  8
• 1 Removing and installing engine
  8
• 1.1 Removing engine
  8
• 1.2 Separating engine and gearbox
  23
• 1.3 Securing engine on engine and gearbox support
  28
• 1.4 Installing engine
  29
• 2 Assembly mountings
  34
• 2.1 Assembly overview - assembly mountings
  34
• 2.2 Removing and installing engine mounting
  38
• 2.3 Supporting engine in installation position
  41
• 2.4 Adjusting assembly mountings
  43
• 3 Engine cover panel
  49
• 3.1 Removing and installing engine cover
  49
• Crankshaft group
  51
• 1 Cylinder block (pulley end)
  51
• 1.1 Assembly overview - poly V-belt drive
  51
• 1.2 Assembly overview - cylinder block (pulley end)
  53
• 1.3 Assembly overview - sealing flange, belt pulley end
  56
• 1.4 Removing and installing poly-V belt
  57
• 1.5 Removing and installing tensioner for poly V-belt
  60
• 1.6 Removing and installing bracket for ancillaries
  62
• 1.7 Removing and installing vibration damper
  65
• 1.8 Removing and installing engine bracket
  66
• 1.9 Renewing crankshaft oil seal - belt pulley end
  70
• 1.10 Removing and installing sealing flange on pulley end
  72
• 2 Cylinder block, gearbox end
  78
• 2.1 Assembly overview - cylinder block, gearbox end
  78
• 2.2 Removing and installing flywheel
  79
• 2.3 Removing and installing sealing flange on gearbox side
  80
• 3 Crankshaft
  91
• 3.1 Assembly overview - crankshaft
  91
• 3.2 Crankshaft dimensions
  92
• 3.3 Measuring axial clearance of crankshaft
  93
• 3.4 Measuring radial clearance of crankshaft
  94
• 3.5 Renewing needle bearing in crankshaft
  94
• 4 Pistons and conrods
  97
• 4.1 Assembly overview - pistons and conrods
  97
• 4.2 Measuring piston projection at TDC
  100
• 4.3 Checking pistons and cylinder bores
  101
• 4.4 Separating new conrod
  104
• 4.5 Checking radial clearance of conrods
  104
• 4.6 Removing and installing oil spray jets
  105
• Cylinder head, valve gear
  107
• 1 Cylinder head
  107
• 1.1 Assembly overview - cylinder head
  107
• 1.2 Assembly overview - cylinder head cover
  111
• 1.3 Removing and installing cylinder head
  113
• 1.4 Removing and installing cylinder head cover
  130
• 1.5 Removing and installing injector seals
  133
• 1.6 Removing and installing vacuum pump
  136
• 1.7 Checking compression
  137
• 2 Fully enclosing toothed belt guard
  140
• 2.1 Assembly overview - fully enclosing toothed belt guard
  140
• 2.2 Removing and installing upper toothed belt guard (fully enclosing)
  142
• 2.3 Removing and installing lower toothed belt guard (fully enclosed)
  143
• 2.4 Removing and installing rear toothed belt guard (fully enclosing)
  144
• 3 Toothed belt drive
  149
• 3.1 Assembly overview - toothed belt
  149
• 3.2 Removing and installing toothed belt
  152
• 4 Valve gear
  170
• 4.1 Assembly overview - valve gear
  170
• 4.2 Measuring axial play of camshaft
  173
• 4.3 Measuring radial play of camshaft
  175
• 4.4 Removing and installing camshaft
  175
• 4.5 Removing and installing camshaft oil seal
  185
• 4.6 Checking hydraulic compensation elements
  191
• 4.7 Removing and installing valve stem seals
  192
• 5 Inlet and exhaust valves
  201
• 5.1 Reworking valve seats
  201
• 5.2 Checking valve guides
  201
• 5.3 Checking valves
  202
• 5.4 Valve dimensions
  203
• Lubrication
  204
• 1 Sump, oil pump
  204
• 1.1 Assembly overview - sump/oil pump
  204
• 1.2 Engine oil:
  207
• 1.3 Removing and installing oil sump
  208
• 1.4 Removing and installing oil pump
  213
• 1.5 Removing and installing oil level and oil temperature sender G266
  214
• 2 Engine oil cooler
  216
• 2.1 Removing and installing engine oil cooler
  216
• 2.2 Checking engine oil cooler for leaks
  220
• 3 Oil filter, oil pressure switch
  223
• 3.1 Assembly overview - oil filter housing, oil pressure switch
  223
• 3.2 Removing and installing oil pressure switch F1
  225
• 3.3 Checking oil pressure and oil pressure switch
  226
• 3.4 Removing and installing oil filter housing
  228
• 4 Oil circuit
  233
• 4.1 Assembly overview - oil circuit
  233
• 4.2 Removing and installing oil supply line
  233
• Cooling
  240
• 1 Cooling system/coolant
  240
• 1.1 Connection diagram - coolant hoses
  240
• 1.2 Checking cooling system for leaks
  241
• 1.3 Draining and adding coolant
  244
• 2 Coolant pump, regulation of cooling system
  254
• 2.1 Assembly overview - coolant pump, thermostat
  254
• 2.2 Removing and installing coolant circulation pump 2 V178
  254
• 2.3 Removing and installing coolant pump
  257
• 2.4 Removing and installing 4/2-way valve with thermostat
  258
• 2.5 Removing and installing coolant temperature sender G62
  261
• 2.6 Removing and installing radiator outlet coolant temperature sender G83
  262
• 3 Coolant pipes
  265
• 3.1 Assembly overview - coolant pipes
  265
• 3.2 Removing and installing coolant pipes
  267
• 3.3 Removing and installing upper coolant pipes
  277
• 4 Radiator, radiator fan
  279
• 4.1 Assembly overview - radiator/radiator fan
  279
• 4.2 Removing and installing radiator
  281
• 4.3 Removing and installing radiator cowl with radiator fan
  282
• 4.4 Removing and installing radiator fan VX57
  283
• 4.5 Removing and installing radiator fan 2 V177
  284
• Turbocharging/supercharging
  286
• 1 Turbocharger
  286
• 1.1 Assembly overview - turbocharger
  286
• 1.2 Removing and installing turbocharger
  290
• 1.3 Renewing vacuum unit for turbocharger
  297
• 2 Charge air system
  306
• 2.1 Assembly overview - charge air system
  306
• 2.2 Assembly overview - charge-air hose connections
  308
• 2.3 Removing and installing charge air cooler
  310
• 2.4 Removing and installing air pipe
  312
• 2.6 Checking charge air system for leaks
  315
• Mixture preparation - injection
  319
• 1 Injection system
  319
• 1.1 Schematic overview - fuel system
  319
• 1.2 Overview of fitting locations - injection system
  321
• 1.3 Filling/bleeding fuel system
  331
• 1.4 Checking fuel system for leaks
  332
• 2 Vacuum system
  334
• 2.1 Connection diagram – vacuum system
  334
• 2.2 Checking vacuum system
  335
• 2.3 Removing and installing charge pressure control solenoid valve N75
  344
• 3 Injectors/high-pressure accumulator (rail)
  347
• 3.1 Assembly overview - injectors
  347
• 3.2 Adapting correction values for injectors
  350
• 3.3 Testing injectors
  351
• 3.4 Checking return flow rate of injectors with engine running
  351
• 3.5 Checking return flow rate of injectors at starter speed
  354
• 3.6 Testing jammed-open injectors
  356
• 3.7 Removing and installing injectors
  358
• 3.8 Removing and installing high-pressure lines
  363
• 3.9 Removing and installing fuel rail
  369
• 4 Air filter
  375
• 4.1 Assembly overview - air filter housing
  375
• 4.2 Removing and installing air filter housing
  377
• 5 Intake manifold
  380
• 5.1 Assembly overview – intake manifold
  380
• 5.2 Removing and installing intake manifold
  382
• 5.3 Removing and installing throttle valve module GX3
  386
• 6 Senders and sensors
  389
• 6.1 Removing and installing exhaust gas pressure sensor 1 G450
  389
• 6.2 Removing and installing air mass meter G70
  390
• 6.3 Checking fuel pressure regulating valve N276
  391
• 6.4 Removing and installing fuel pressure regulating valve N276
  392
• 6.5 Removing and installing fuel pressure sender G247
  396
• 7 Engine control unit
  399
• 7.1 Removing and installing engine control unit J623
  399
• 7.2 Removing and installing engine (motor) control unit J623 with protective housing
  401
• 8 High-pressure pump
  405
• 8.1 Assembly overview - high-pressure pump
  405
• 8.2 Removing and installing high-pressure pump
  407
• 8.3 Checking high-pressure pump
  411
• 9 Lambda probe
  414
• 9.1 Removing and installing Lambda probe
  414
• Exhaust system
  416
• 1 Exhaust pipes and silencers
  416
• 1.1 Assembly overview – silencers
  416
• 1.2 Separating exhaust pipes from silencers
  417
• 1.3 Aligning exhaust system free of stress
  419
• 1.4 Installation position of clamp
  420
• 2 Emission control
  422
• 2.1 Assembly overview – emission control
  422
• 2.2 Removing and installing particulate filter
  425
• 3 Exhaust gas temperature regulation
  436
• 3.1 Assembly overview – exhaust gas temperature regulation
  436
• 3.2 Removing and installing exhaust gas temperature sender 1 G235
  437
• 3.3 Removing and installing exhaust gas temperature sender 3 G495
  438
• 3.4 Removing and installing exhaust gas temperature sender 4 G648
  440
• 4 Exhaust gas recirculation
  443
• 4.1 Assembly overview – exhaust gas recirculation
  443
• 4.2 Removing and installing exhaust gas recirculation cooler
  445
• 4.3 Checking changeover for exhaust gas recirculation cooler
  448
• 4.4 Checking exhaust gas recirculation cooler for leaks
  449
• 4.5 Cleaning exhaust gas recirculation system
  449
• Glow plug system
  459
• 1 Glow plug system
  459
• 1.1 Removing and installing glow plug
  459
• 1.2 Removing and installing automatic glow period control unit J179
  461
• 1.3 Removing and installing engine speed sender G28
  461
• 1.4 Removing and installing Hall sender G40
  462