4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288)

Kapitelübersicht

• 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
  2
• 1.4 Safety precautions when working on the cooling system
  2
• 1.5 Safety precautions when working on SCR system
  2
• 1.6 Safety precautions when working on exhaust system
  3
• 2 Identification
  5
• 2.1 Engine number/engine data
  5
• 3 Repair instructions
  7
• 3.1 Rules for cleanliness
  7
• 3.2 Foreign objects in engine
  7
• 3.3 Contact corrosion
  7
• 3.4 Routing and attachment of lines
  8
• 3.5 Fitting radiator and condensers
  8
• Removing and installing engine
  9
• 1 Removing and installing engine
  9
• 1.1 Removing engine
  9
• 1.2 Separating engine and gearbox
  21
• 1.3 Securing engine on engine and gearbox support
  24
• 1.4 Installing engine
  25
• 2 Assembly mountings
  30
• 2.1 Assembly overview - assembly mountings
  30
• 2.2 Removing and installing engine mounting
  34
• 2.3 Removing and installing gearbox mounting
  36
• 2.4 Removing and installing pendulum support
  40
• 2.5 Supporting engine in installation position
  41
• 2.6 Adjusting assembly mountings
  58
• 2.7 Checking adjustment of assembly mountings
  61
• 3 Engine cover panel
  62
• 3.1 Removing and installing engine cover
  62
• Crankshaft group
  63
• 1 Cylinder block (pulley end)
  63
• 1.1 Assembly overview - cylinder block (pulley end)
  63
• 1.2 Assembly overview - sealing flange, belt pulley end
  66
• 1.3 Removing and installing poly-V belt
  68
• 1.4 Removing and installing tensioner for poly V-belt
  69
• 1.5 Removing and installing vibration damper
  70
• 1.6 Removing and installing bracket for ancillaries
  71
• 1.7 Removing and installing engine support
  73
• 1.8 Removing and installing sealing flange on pulley end
  75
• 1.9 Renewing caps in cylinder block (pulley end)
  78
• 2 Cylinder block, gearbox end
  81
• 2.1 Assembly overview - cylinder block, gearbox end
  81
• 2.2 Removing and installing flywheel
  84
• 2.3 Removing and installing sealing flange on gearbox side
  86
• 2.4 Renewing caps in cylinder block (gearbox end)
  96
• 3 Crankshaft
  98
• 3.1 Assembly overview - crankshaft
  98
• 3.2 Crankshaft dimensions
  98
• 3.3 Renewing needle bearing in crankshaft
  98
• 3.4 Measuring axial clearance of crankshaft
  101
• 4 Pistons and conrods
  103
• 4.1 Assembly overview - pistons and conrods
  103
• 4.2 Removing and installing pistons
  106
• 4.3 Measuring piston projection at TDC
  108
• 4.4 Checking pistons and cylinder bores
  110
• 4.5 Separating new conrod
  112
• 4.6 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
  121
• 1.4 Removing and installing cylinder head cover
  128
• 1.5 Removing and installing injector seals
  131
• 1.6 Removing and installing camshaft housing
  133
• 1.7 Checking compression
  137
• 2 Toothed belt drive
  140
• 2.1 Assembly overview - toothed belt cover
  140
• 2.2 Assembly overview - toothed belt
  140
• 2.3 Removing and installing toothed belt guard
  142
• 2.4 Removing and installing toothed belt
  148
• 2.5 Removing toothed belt from camshaft
  163
• 3 Valve gear
  169
• 3.1 Assembly overview - valve gear
  169
• 3.2 Measuring axial play of camshaft
  172
• 3.3 Removing and installing camshaft oil seal
  172
• 3.4 Checking hydraulic compensation elements
  175
• 3.5 Removing and installing valve stem seals
  176
• 4 Inlet and exhaust valves
  184
• 4.1 Checking valve guides
  184
• 4.2 Checking valves
  185
• 4.3 Valve dimensions
  185
• Lubrication
  186
• 1 Sump, oil pump
  186
• 1.1 Assembly overview - sump/oil pump
  186
• 1.2 Engine oil:
  188
• 1.3 Removing and installing oil sump
  188
• 1.4 Removing and installing oil pump
  193
• 1.5 Removing and installing oil level and oil temperature sender G266
  194
• 2 Engine oil cooler
  196
• 3 Oil filter, oil pressure switch
  197
• 3.1 Assembly overview - oil filter housing, oil pressure switch
  197
• 3.2 Removing and installing oil pressure switch F1
  199
• 3.3 Removing and installing oil pressure switch for reduced oil pressure F378
  201
• 3.4 Checking oil pressure
  203
• 3.5 Removing and installing oil filter housing
  203
• 3.6 Removing and installing oil pressure regulating valve N428
  206
• Cooling
  209
• 1 Cooling system/coolant
  209
• 1.1 Connection diagram - coolant hoses
  209
• 1.2 Checking cooling system for leaks
  211
• 1.3 Draining coolant
  215
• 1.4 Filling with coolant
  217
• 1.5 Checking filling quality of cooling system
  237
• 1.6 Flushing cooling system
  239
• 2 Coolant pump, regulation of cooling system
  264
• 2.1 Assembly overview - coolant pump, thermostat
  264
• 2.2 Assembly overview - electric coolant pump
  268
• 2.3 Assembly overview - coolant temperature sender
  270
• 2.4 Assembly overview - actuator for engine temperature regulation N493
  271
• 2.5 Removing and installing electric coolant pump
  273
• 2.6 Removing and installing coolant pump
  279
• 2.7 Removing and installing thermostat
  280
• 2.8 Checking thermostat
  284
• 2.9 Removing and installing coolant valve for cylinder head N489
  285
• 2.10 Removing and installing coolant temperature sender G62
  285
• 2.11 Removing and installing coolant temperature sender 2 G802
  287
• 2.12 Removing and installing actuator for engine temperature regulation N493
  289
• 3 Coolant pipes
  296
• 3.1 Assembly overview - coolant pipes
  296
• 3.2 Removing and installing coolant pipes
  300
• 4 Radiator, radiator fan
  325
• 4.1 Assembly overview - radiator/radiator fan
  325
• 4.2 Assembly overview - auxiliary radiator
  327
• 4.3 Assembly overview – radiator cowl and radiator fan
  328
• 4.4 Removing and installing radiator
  329
• 4.5 Removing and installing water radiator for charge air cooling circuit
  332
• 4.6 Removing and installing radiator cowl
  335
• 4.7 Removing and installing radiator fan
  338
• 4.8 Removing and installing auxiliary radiator
  339
• Turbocharging/supercharging
  343
• 1 Turbocharger
  343
• 1.1 Assembly overview - turbocharger
  343
• 1.2 Removing and installing turbocharger
  356
• 1.3 Removing and installing vacuum unit for turbocharger
  368
• 1.4 Removing and installing turbocharger 1 control unit J724
  374
• 2 Charge air system
  379
• 2.1 Assembly overview - charge air system
  379
• 2.2 Removing and installing charge pressure sender G31
  381
• 2.3 Removing and installing charge pressure sender 2 G447
  381
• 2.4 Checking charge air system for leaks
  382
• 2.5 Removing and installing air pipe
  384
• 2.6 Checking charge air cooler for leaks
  391
• Mixture preparation - injection
  397
• 1 Injection system
  397
• 1.1 Schematic overview - fuel system
  397
• 1.2 Overview of fitting locations - injection system
  398
• 1.3 Filling/bleeding fuel system
  412
• 1.4 Checking fuel system for leaks
  412
• 2 Vacuum system
  414
• 2.1 Connection diagram – vacuum system
  414
• 2.2 Checking vacuum system
  417
• 3 Injectors/high-pressure accumulator (rail)
  419
• 3.1 Assembly overview - injectors
  419
• 3.2 Assembly overview - fuel rail
  421
• 3.3 Adapting correction values for injectors
  423
• 3.4 Testing injectors
  424
• 3.5 Checking return flow rate of injectors with engine running
  424
• 3.6 Checking return flow rate of injectors at starter speed
  427
• 3.7 Removing and installing injectors
  429
• 3.8 Removing and installing high-pressure lines
  433
• 3.9 Removing and installing fuel rail
  439
• 4 Air filter
  443
• 4.1 Assembly overview - air filter housing
  443
• 4.2 Removing and installing air filter housing
  445
• 5 Intake manifold
  449
• 5.1 Assembly overview – intake manifold
  449
• 5.2 Removing and installing intake manifold
  452
• 5.3 Removing and installing throttle valve module J338
  458
• 6 Senders and sensors
  461
• 6.1 Removing and installing fuel pressure regulating valve N276
  461
• 6.2 Checking fuel pressure regulating valve N276
  463
• 6.3 Removing and installing fuel pressure sender G247
  465
• 6.4 Removing and installing air mass meter G70
  466
• 6.5 Removing and installing pressure differential sender G505
  468
• 6.6 Removing and installing exhaust gas pressure sensor 1 G450
  469
• 6.9 Removing and installing fuel temperature sender G81
  472
• 6.10 Removing and installing control unit for NOx sender GX30
  473
• 6.11 Assembly overview - NOx sender control unit GX30
  477
• 6.12 Removing and installing control unit 2 for NOx sender GX46
  478
• 6.13 Removing and installing particle sensor G784
  480
• 7 Engine control unit
  482
• 7.1 Removing and installing engine control unit J623
  482
• 8 High-pressure pump
  490
• 8.1 Assembly overview - high-pressure pump
  490
• 8.2 Removing and installing high-pressure pump
  492
• 9 Lambda probe
  496
• 9.1 Assembly overview - Lambda probe
  496
• 9.2 Removing and installing Lambda probe
  496
• Exhaust system
  499
• 1 Exhaust pipes and silencers
  499
• 1.1 Assembly overview – silencers
  499
• 1.2 Removing and installing front exhaust pipe
  503
• 1.3 Removing and installing rear silencer
  506
• 1.4 Aligning exhaust system free of stress
  510
• 1.5 Checking exhaust system for leaks
  510
• 1.6 Installation position of clamp
  511
• 1.7 Assembly overview - front exhaust pipe
  511
• 2 Emission control
  518
• 2.1 Assembly overview – emission control
  518
• 2.2 Removing and installing emission control module
  525
• 2.3 Removing and installing exhaust flap control unit J883
  529
• 3 SCR system (selective catalytic reduction)
  532
• 3.1 Assembly overview – reducing agent tank
  532
• 3.2 Assembly overview - reducing agent supply line
  536
• 3.3 Assembly overview - delivery module for reducing agent
  537
• 3.4 Removing and installing reducing agent tank
  538
• 3.5 Removing and installing front section of reducing agent supply line
  544
• 3.6 Removing and installing delivery module for reducing agent
  559
• 3.7 Removing and installing injector for reduction agent N474
  561
• 3.8 Removing and installing control unit for reducing-agent heater J891
  564
• 3.9 Assembly overview - injector for reducing agent
  568
• 3.10 Draining reducing agent tank
  569
• 3.11 Removing and installing rear section of reducing agent supply line
  576
• 3.12 Removing and installing filler pipe for reducing agent tank
  578
• 3.13 Disconnecting reducing agent supply line
  582
• 3.14 SCR - resetting learnt values
  585
• 4 Exhaust gas temperature regulation
  586
• 4.1 Assembly overview – exhaust gas temperature regulation
  586
• 4.2 Removing and installing exhaust gas temperature sender 1 G235
  588
• 4.3 Removing and installing exhaust gas temperature sender 2 G448
  594
• 4.4 Removing and installing exhaust gas temperature sender 3 G495
  596
• 4.5 Removing and installing exhaust gas temperature sender 4 G648
  597
• 5 Exhaust gas recirculation
  600
• 5.1 Assembly overview – exhaust gas recirculation
  600
• 5.2 Removing and installing exhaust gas recirculation cooler
  603
• 5.3 Removing and installing exhaust gas recirculation valve 1 GX5
  609
• 5.4 Removing and installing exhaust gas recirculation valve 2 GX6
  611
• 5.5 Checking exhaust gas recirculation cooler for leaks
  614
• 6 Exhaust manifold
  615
• 6.1 Assembly overview - exhaust manifold
  615
• 6.2 Removing and installing exhaust manifold
  616
• Glow plug system
  618
• 1 Glow plug system
  618
• 1.1 Assembly overview – glow plug system
  618
• 1.2 Removing and installing glow plug
  619
• 1.3 Removing and installing automatic glow period control unit J179
  623
• 1.4 Removing and installing Hall sender G40
  623
• 1.5 Removing and installing engine speed sender G28
  624