4-cylinder common rail engine (2.0 l, 4V, turbocharger, 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
  1
• 1.4 Safety precautions when working on the cooling system
  2
• 1.5 Safety precautions when working on exhaust system
  2
• 2 Identification
  4
• 2.1 Motor number/motor data
  4
• 3 Repair instructions
  6
• 3.1 Rules for cleanliness
  6
• 3.2 Foreign objects in engine
  6
• 3.3 Contact corrosion
  6
• 3.4 Routing and attachment of lines
  7
• 3.5 Fitting radiator and condensers
  7
• 4 Technical data
  9
• 4.1 Coolant
  10
• Removing and installing engine
  12
• 1 Removing and installing engine
  12
• 1.1 Removing engine
  12
• 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
  35
• 2.1 Assembly overview - assembly mountings
  35
• 2.2 Removing and installing engine mounting
  40
• 2.3 Removing and installing gearbox mounting
  41
• 2.4 Removing and installing pendulum support
  43
• 2.5 Supporting engine in installation position
  44
• 2.6 Adjusting assembly mountings
  49
• 2.7 Checking adjustment of assembly mountings
  52
• 3 Engine cover panel
  53
• 3.1 Removing and installing engine cover
  53
• Crankshaft group
  54
• 1 Cylinder block (pulley end)
  54
• 1.1 Assembly overview - cylinder block (pulley end)
  54
• 1.2 Removing and installing poly-V belt
  56
• 1.3 Removing and installing tensioner for poly V-belt
  58
• 1.4 Removing and installing vibration damper
  59
• 1.5 Removing and installing engine support
  59
• 1.6 Removing and installing bracket for ancillaries
  61
• 1.7 Assembly overview - sealing flange, belt pulley end
  63
• 1.8 Removing and installing sealing flange on pulley end
  64
• 1.9 Renewing caps in cylinder block (pulley end)
  67
• 2 Cylinder block, gearbox end
  69
• 2.1 Assembly overview - cylinder block, gearbox end
  69
• 2.2 Removing and installing flywheel
  70
• 2.3 Removing and installing sealing flange on gearbox side
  73
• 2.4 Renewing caps in cylinder block (gearbox end)
  84
• 3 Crankshaft
  86
• 3.1 Assembly overview - crankshaft
  86
• 3.2 Crankshaft dimensions
  87
• 3.3 Measuring axial clearance of crankshaft
  88
• 3.4 Renewing needle bearing in crankshaft
  89
• 4 Pistons and conrods
  92
• 4.1 Assembly overview - pistons and conrods
  92
• 4.2 Removing and installing pistons
  96
• 4.3 Measuring piston projection at TDC
  97
• 4.4 Checking pistons and cylinder bores
  100
• 4.5 Checking radial clearance of conrods
  102
• Cylinder head, valve gear
  103
• 1 Toothed belt drive
  103
• 1.1 Assembly overview - toothed belt cover
  103
• 1.2 Assembly overview - toothed belt
  104
• 1.3 Removing and installing toothed belt guard
  106
• 1.4 Removing toothed belt from camshaft
  112
• 1.5 Removing and installing toothed belt
  116
• 2 Cylinder head
  131
• 2.1 Assembly overview - cylinder head cover
  131
• 2.2 Assembly overview - cylinder head
  133
• 2.3 Removing and installing cylinder head cover
  137
• 2.4 Removing and installing cylinder head
  140
• 2.5 Removing and installing injector seals
  152
• 2.6 Checking compression
  153
• 2.7 Removing and installing camshaft housing
  155
• 3 Valve gear
  163
• 3.1 Assembly overview - valve gear
  163
• 3.2 Measuring axial play of camshaft
  167
• 3.3 Removing and installing camshaft oil seal
  168
• 3.4 Removing and installing camshaft adjuster
  170
• 3.5 Removing and installing camshaft control valve 1 N205
  177
• 3.6 Checking hydraulic compensation elements
  177
• 3.7 Removing and installing valve stem seals
  178
• 4 Inlet and exhaust valves
  189
• 4.1 Checking valve guides
  189
• 4.2 Checking valves
  190
• 4.3 Valve dimensions
  190
• Lubrication
  191
• 1 Sump, oil pump
  191
• 1.1 Assembly overview - sump/oil pump
  191
• 1.2 Removing and installing oil level and oil temperature sender G266
  194
• 1.3 Removing and installing oil sump
  195
• 1.4 Removing and installing oil pump
  199
• 1.5 Engine oil:
  200
• 2 Engine oil cooler
  201
• 3 Oil filter, oil pressure switch
  202
• 3.1 Assembly overview - oil filter housing, oil pressure switch
  202
• 3.2 Removing and installing oil filter housing
  204
• 3.3 Removing and installing oil pressure switch F1
  207
• 3.4 Removing and installing oil pressure switch for reduced oil pressure F378
  209
• 3.5 Removing and installing oil pressure regulating valve N428
  211
• 3.6 Checking oil pressure
  212
• Cooling
  213
• 1 Cooling system/coolant
  213
• 1.1 Connection diagram - coolant hoses
  213
• 1.2 Checking cooling system for leaks
  219
• 1.3 Draining coolant
  222
• 1.4 Filling with coolant
  224
• 1.5 Checking filling quality of cooling system
  236
• 1.6 Checking electric vacuum pump VAS 6096/2
  238
• 1.7 Flushing cooling system
  239
• 2 Coolant pump, regulation of cooling system
  263
• 2.1 Assembly overview - coolant pump, thermostat
  263
• 2.2 Assembly overview - electric coolant pump
  267
• 2.3 Assembly overview - coolant temperature sender
  272
• 2.4 Removing and installing electric coolant pump
  273
• 2.5 Removing and installing coolant pump
  288
• 2.6 Removing and installing thermostat
  289
• 2.7 Checking thermostat
  293
• 2.8 Removing and installing coolant valve for cylinder head N489
  293
• 2.9 Removing and installing coolant temperature sender G62
  294
• 3 Coolant pipes
  296
• 3.1 Assembly overview - coolant pipes
  296
• 3.2 Removing and installing coolant pipes
  298
• 4 Radiator, radiator fan
  314
• 4.1 Assembly overview - radiator/radiator fan
  314
• 4.2 Assembly overview – radiator cowl and radiator fan
  318
• 4.3 Removing and installing radiator
  320
• 4.4 Removing and installing water radiator for charge air cooling circuit
  321
• 4.5 Removing and installing radiator cowl
  324
• 4.6 Removing and installing radiator fan
  325
• Turbocharging/supercharging
  327
• 1 Turbocharger
  327
• 1.1 Assembly overview - turbocharger
  327
• 1.2 Removing and installing turbocharger
  330
• 1.3 Renewing vacuum unit for turbocharger
  336
• 1.4 Removing and installing connecting piece
  344
• 2 Charge air system
  346
• 2.1 Assembly overview - charge air system
  346
• 2.2 Removing and installing charge pressure sender G31
  349
• 2.3 Checking charge air system for leaks
  349
• 2.4 Removing and installing air pipe
  352
• 2.5 Checking charge air cooler for leaks
  353
• Mixture preparation - injection
  358
• 1 Injection system
  358
• 1.1 Overview of fitting locations - injection system
  358
• 1.2 Schematic overview - fuel system
  364
• 1.3 Filling/bleeding fuel system
  366
• 1.4 Checking fuel system for leaks
  366
• 2 Vacuum system
  368
• 2.1 Connection diagram – vacuum system
  368
• 2.2 Checking vacuum system
  369
• 3 Injectors/high-pressure accumulator (rail)
  370
• 3.1 Assembly overview - injectors
  370
• 3.2 Assembly overview - fuel rail
  372
• 3.3 Adapting correction values for injectors
  373
• 3.4 Testing injectors
  374
• 3.5 Checking return flow rate of injectors with engine running
  375
• 3.6 Checking return flow rate of injectors at starter speed
  378
• 3.7 Testing jammed-open injectors
  379
• 3.8 Removing and installing injectors
  381
• 3.9 Removing and installing high-pressure lines
  385
• 3.10 Removing and installing fuel rail
  388
• 4 Air filter
  390
• 4.1 Assembly overview - air filter housing
  390
• 4.2 Removing and installing air filter housing
  392
• 5 Intake manifold
  396
• 5.1 Assembly overview – intake manifold
  396
• 5.2 Removing and installing intake manifold
  400
• 5.3 Removing and installing throttle valve module J338
  404
• 6 Senders and sensors
  408
• 6.1 Removing and installing fuel pressure regulating valve N276
  408
• 6.2 Checking fuel pressure regulating valve N276
  412
• 6.3 Removing and installing fuel pressure sender G247
  414
• 6.4 Removing and installing air mass meter G70
  415
• 6.5 Removing and installing pressure differential sender G505
  417
• 6.6 Removing and installing exhaust gas pressure sensor 1 G450
  418
• 6.9 Removing and installing fuel temperature sender G81
  420
• 7 Engine control unit
  423
• 7.1 Removing and installing engine control unit J623
  423
• 7.2 Removing and installing engine (motor) control unit J623 with protective housing
  427
• 8 High-pressure pump
  436
• 8.1 Assembly overview - high-pressure pump
  436
• 8.2 Removing and installing high-pressure pump
  437
• 9 Lambda probe
  442
• 9.1 Assembly overview - Lambda probe
  442
• 9.2 Removing and installing Lambda probe
  445
• Exhaust system
  450
• 1 Exhaust pipes and silencers
  450
• 1.1 Assembly overview – silencers
  450
• 1.2 Removing and installing front exhaust pipe
  456
• 1.3 Separating exhaust pipes from silencers
  457
• 1.4 Removing and installing rear silencer
  459
• 1.5 Aligning exhaust system free of stress
  460
• 1.6 Checking exhaust system for leaks
  462
• 1.7 Installation position of clamp
  462
• 1.8 Align end exhaust pipes
  466
• 2 Emission control
  467
• 2.1 Assembly overview – emission control
  467
• 2.2 Removing and installing emission control module
  472
• 2.3 Removing and installing catalytic converter
  490
• 2.4 Removing and installing exhaust flap control unit J883
  490
• 3 Exhaust gas temperature regulation
  492
• 3.1 Assembly overview – exhaust gas temperature regulation
  492
• 3.2 Removing and installing exhaust gas temperature sender 1 G235
  496
• 3.3 Removing and installing exhaust gas temperature sender 2 G448
  498
• 3.4 Removing and installing exhaust gas temperature sender 3 G495
  503
• 3.5 Removing and installing exhaust gas temperature sender 4 G648
  509
• 4 Exhaust gas recirculation
  515
• 4.1 Assembly overview – exhaust gas recirculation
  515
• 4.2 Assembly overview - exhaust gas recirculation valve 1 GX5
  517
• 4.3 Removing and installing exhaust gas recirculation cooler
  518
• 4.4 Removing and installing exhaust gas recirculation valve 1 GX5
  521
• 4.5 Removing and installing exhaust gas recirculation valve 2 GX6
  523
• 4.6 Checking exhaust gas recirculation cooler for leaks
  524
• Glow plug system
  525
• 1 Glow plug system
  525
• 1.1 Assembly overview – glow plug system
  525
• 1.2 Removing and installing glow plug
  526
• 1.3 Removing and installing automatic glow period control unit J179
  530
• 1.4 Removing and installing Hall sender G40
  530
• 1.5 Removing and installing engine speed sender G28
  531