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

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety regulations for working on fuel supply
  1
• 1.2 Safety measures when working on vehicles with start/stop system
  1
• 1.4 Safety precautions when working on the cooling system
  2
• 1.5 Safety precautions when working on ignition system
  2
• 1.6 Safety precautions when working on exhaust system
  3
• 2 Identification
  4
• 2.1 Engine number/engine data
  4
• 3 Repair instructions
  5
• 3.1 Rules for cleanliness
  5
• 3.2 General notes
  5
• 3.3 General repair notes
  6
• 3.4 Foreign objects in engine
  6
• 3.5 Contact corrosion
  6
• 3.6 Routing and attachment of lines
  7
• 3.7 Fitting radiator and condensers
  7
• 3.8 Checking vacuum system
  7
• Removing and installing engine
  14
• 1 Removing and installing engine
  14
• 1.1 Removing engine
  14
• 1.2 Securing engine on engine and gearbox support
  31
• 1.3 Installing engine
  34
• 1.4 Modifying engine bracket T10229
  37
• 1.5 Converting adapter 10 - 222 A /23 with adapter 10 - 222 A /23-1
  38
• 2 Assembly mountings
  40
• 2.1 Assembly overview – assembly mountings
  40
• 2.2 Supporting engine in installation position
  42
• 2.3 Removing and installing engine mounting
  43
• 2.4 Removing and installing engine mounting
  49
• Crankshaft group
  54
• 1 Cylinder block (pulley end)
  54
• 1.1 Assembly overview - cylinder block (pulley end)
  54
• 1.2 Assembly overview - sealing flange, belt pulley end
  56
• 1.3 Assembly overview - poly V-belt drive
  58
• 1.4 Removing and installing poly-V belt
  64
• 1.5 Removing and installing tensioner for poly V-belt
  66
• 1.6 Removing and installing bracket for ancillaries
  67
• 1.7 Removing and installing vibration damper
  70
• 1.8 Renewing crankshaft oil seal - belt pulley end
  71
• 1.9 Removing and installing sealing flange on pulley end
  74
• 2 Cylinder block, gearbox end
  79
• 2.1 Assembly overview - cylinder block, gearbox end
  79
• 2.2 Removing and installing flywheel
  80
• 2.3 Removing and installing sealing flange on gearbox side
  82
• 3 Crankshaft
  94
• 3.1 Assembly overview - crankshaft
  94
• 3.2 Crankshaft dimensions
  95
• 3.3 Allocation of main bearing shells
  96
• 3.4 Measuring axial clearance of crankshaft
  96
• 3.5 Measuring radial clearance of crankshaft
  97
• 3.6 Renewing needle bearing in crankshaft
  98
• 3.7 Renewing spur gear for crankshaft
  99
• 4 Pistons and conrods
  104
• 4.1 Assembly overview - pistons and conrods
  104
• 4.2 Removing and installing pistons
  107
• 4.3 Separating new conrod
  108
• 4.4 Checking pistons and cylinder bores
  109
• 4.5 Checking radial clearance of conrods
  110
• 4.6 Measuring piston projection at TDC
  111
• 4.7 Removing and installing oil spray jets
  113
• Cylinder head, valve gear
  115
• 1 Cylinder head
  115
• 1.1 Assembly overview - cylinder head
  115
• 1.2 Assembly overview - cylinder head cover
  119
• 1.3 Removing and installing cylinder head
  124
• 1.4 Removing and installing cylinder head cover
  136
• 1.5 Removing and installing injector seals
  143
• 1.6 Removing and installing vacuum pump
  147
• 1.7 Checking compression
  151
• 2 Fully enclosing toothed belt guard
  153
• 2.1 Assembly overview - fully enclosing toothed belt guard
  153
• 2.2 Removing and installing fully enclosing toothed belt guard
  156
• 3 Toothed belt drive
  162
• 3.1 Assembly overview - toothed belt
  162
• 3.2 Removing and installing toothed belt
  164
• 4 Valve gear
  181
• 4.1 Assembly overview - valve gear
  181
• 4.2 Measuring axial play of camshaft
  184
• 4.3 Measuring radial play of camshaft
  185
• 4.4 Removing and installing camshaft oil seal
  185
• 4.5 Removing and installing camshaft
  188
• 4.6 Checking hydraulic compensation elements
  198
• 4.7 Removing and installing valve stem seals
  199
• 5 Inlet and exhaust valves
  204
• 5.1 Reworking valve seats
  204
• 5.2 Checking valve guides
  204
• 5.3 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 Engine oil:
  219
• 1.5 Removing and installing oil level and oil temperature sender G266
  220
• 2 Engine oil cooler
  222
• 2.1 Assembly overview - engine oil cooler
  222
• 2.2 Removing and installing engine oil cooler
  224
• 2.3 Checking engine oil cooler for leaks
  228
• 3 Oil filter, oil pressure switch
  231
• 3.1 Assembly overview - oil filter housing
  231
• 3.2 Removing and installing oil pressure switch F1
  231
• 3.3 Checking oil pressure
  232
• 3.4 Removing and installing oil filter housing, mono-turbo
  234
• 4 Balancer shaft module
  238
• 4.1 Removing and installing balance shaft module
  238
• Cooling
  246
• 1 Cooling system/coolant
  246
• 1.1 Draining and adding coolant
  246
• 1.2 Checking cooling system for leaks
  255
• 1.3 Assembly overview – cooling system
  257
• 1.4 Connection diagram for coolant hoses - vehicles with basic equipment
  259
• 1.5 Connection diagram for coolant hoses - vehicles with additional heat exchanger
  261
• 1.6 Connection diagram for coolant hoses - vehicles with auxiliary heater
  266
• 2 Coolant pump, regulation of cooling system
  288
• 2.1 Assembly overview - coolant pump and ball thermostat (4/2-way valve)
  288
• 2.2 Assembly overview - electric coolant pump
  288
• 2.3 Removing and installing coolant pump
  289
• 2.4 Removing and installing continued coolant circulation pump V51
  292
• 2.5 Removing and installing 4/2-way valve with thermostat
  294
• 2.6 Removing and installing Y-thermostat
  299
• 2.7 Removing and installing coolant temperature sender G62
  300
• 2.8 Removing and installing radiator outlet coolant temperature sender G83
  303
• 3 Radiator, radiator fan
  308
• 3.1 Assembly overview - radiator/radiator fan
  308
• 3.2 Assembly overview – radiator cowl and radiator fan
  310
• 3.3 Removing and installing radiator
  310
• 3.4 Removing and installing radiator cowl with radiator fan V7
  318
• Turbocharging/supercharging
  320
• 1 Turbocharger
  320
• 1.1 Assembly overview - turbocharger
  320
• 1.2 Assembly overview – connecting pipes (bi-turbo)
  330
• 1.3 Removing and installing turbocharger
  332
• 1.4 Removing and installing exhaust manifold gasket (bi-turbo)
  367
• 1.5 Removing and installing compressor housing and turbine housing (bi-turbo)
  377
• 1.6 Checking vacuum unit for turbocharger
  380
• 1.7 Renewing vacuum unit for turbocharger
  389
• 1.8 Removing and installing connecting pipes (bi-turbo)
  403
• 2 Charge air system
  411
• 2.1 Assembly overview - charge air system
  411
• 2.2 Assembly overview - charge-air hose connections
  415
• 2.3 Removing and installing charge air cooler
  419
• 2.5 Removing and installing exhaust gas flap valve N220
  425
• 2.6 Removing and installing charge pressure control solenoid valve N75
  426
• 2.7 Checking charge air system for leaks
  428
• 2.8 Removing and installing charge pressure sender 2 G447
  432
• Mixture preparation - injection
  434
• 1 Injection system
  434
• 1.1 Overview of fitting locations - injection system
  434
• 1.2 Schematic overview - fuel system
  444
• 1.3 Assembly overview - fuel system
  446
• 1.4 Checking fuel system for leaks
  452
• 2 Vacuum system
  453
• 2.1 Connection diagram – vacuum system
  453
• 2.2 Testing vacuum system for leaks, bi-turbo
  457
• 2.3 Testing vacuum system for leaks, mono-turbo
  466
• 2.4 Checking vacuum system for leaks, “four-wheel drive”
  473
• 3 Injectors/high-pressure accumulator (rail)
  481
• 3.1 Removing and installing fuel rail
  481
• 3.2 Removing and installing high-pressure lines
  485
• 3.3 Removing and installing injectors
  492
• 3.4 Testing injectors
  498
• 3.5 Testing jammed-open injectors
  506
• 3.6 Check pressure retention valve in fuel return line
  508
• 3.7 Checking low pressure fuel system
  511
• 3.8 Checking fuel pump delivery rate
  513
• 4 Air filter
  515
• 4.1 Assembly overview - air filter housing
  515
• 4.2 Removing and installing air filter housing
  518
• 5 Intake manifold
  521
• 5.1 Assembly overview – intake manifold
  521
• 5.2 Removing and installing intake manifold
  521
• 5.3 Removing and installing throttle valve module GX3
  526
• 6 Senders and sensors
  528
• 6.1 Removing and installing air mass meter G70
  528
• 6.2 Removing and installing fuel pressure regulating valve N276
  530
• 6.3 Checking fuel pressure regulating valve N276
  532
• 6.4 Removing and installing fuel pressure sender G247
  534
• 6.5 Removing and installing exhaust gas pressure sensor 1 G450
  536
• 7 Engine/motor control unit
  540
• 7.1 Removing and installing engine control unit J623
  540
• 8 High-pressure pump
  542
• 8.1 Removing and installing high-pressure pump
  542
• 8.2 Checking high-pressure pump
  546
• Exhaust system
  550
• 1 Exhaust pipes and silencers
  550
• 1.1 Assembly overview – silencers
  550
• 1.2 Removing and installing front exhaust pipe
  554
• 1.3 Separating exhaust pipes from silencers
  556
• 1.4 Checking exhaust system for leaks
  557
• 1.5 Aligning exhaust system free of stress
  557
• 1.6 Installation position of clamp
  559
• 2 Emission control
  560
• 2.1 Assembly overview - particulate filter
  560
• 2.2 Assembly overview - catalytic converter, four-wheel drive vehicles
  565
• 2.3 Removing and installing particulate filter
  567
• 2.4 Removing and installing catalytic converter
  573
• 3 Exhaust gas recirculation
  577
• 3.1 Assembly overview – exhaust gas recirculation
  577
• 3.2 Removing and installing exhaust gas recirculation cooler
  580
• 3.3 Removing and installing exhaust gas recirculation valve 1 GX5
  592
• 3.4 Checking exhaust gas recirculation cooler for leaks
  593
• Glow plug system
  597
• 1 Glow plug system
  597
• 1.1 Checking glow plug system
  597
• 1.2 Removing and installing glow plug
  597
• 1.3 Checking glow plug
  600
• 1.4 Optical characteristics of glow plugs
  601
• 1.5 Removing and installing engine speed sender G28
  601
• 1.6 Removing and installing Hall sender G40
  603