3-cylinder common rail engine (1.4 l, 4V, turbocharger, EA 288)

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
  2
• 1.4 Safety precautions when working on the cooling system
  3
• 1.5 Safety precautions when working on exhaust system
  3
• 2 Identification
  5
• 2.1 Motor number/motor 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
• 4 Technical data
  10
• 4.1 Coolant
  11
• Removing and installing engine
  13
• 1 Removing and installing engine
  13
• 1.1 Removing engine
  13
• 1.2 Separating engine and gearbox
  21
• 1.3 Securing engine on engine and gearbox support
  26
• 1.4 Installing engine
  28
• 2 Assembly mountings
  32
• 2.1 Assembly overview - assembly mountings
  32
• 2.2 Supporting engine in installation position
  34
• 2.3 Removing and installing engine mounting
  36
• 2.4 Removing and installing gearbox mounting
  37
• 2.5 Removing and installing pendulum support
  38
• 3 Engine cover panel
  40
• 3.1 Removing and installing engine cover
  40
• Crankshaft group
  41
• 1 Cylinder block (pulley end)
  41
• 1.1 Assembly overview - poly V-belt drive
  41
• 1.2 Assembly overview - sealing flange, belt pulley end
  43
• 1.3 Removing and installing poly-V belt
  44
• 1.4 Removing and installing tensioner for poly V-belt
  45
• 1.5 Removing and installing vibration damper
  46
• 1.6 Removing and installing bracket for ancillaries
  47
• 1.7 Removing and installing engine support
  49
• 1.8 Removing and installing sealing flange on pulley end
  51
• 2 Cylinder block, gearbox end
  54
• 2.1 Assembly overview - cylinder block, gearbox end
  54
• 2.2 Removing and installing flywheel
  55
• 2.3 Removing and installing sealing flange on gearbox side
  58
• 3 Crankshaft
  71
• 3.1 Assembly overview - crankshaft
  71
• 3.2 Crankshaft dimensions
  73
• 3.3 Measuring axial clearance of crankshaft
  73
• 3.4 Renewing needle bearing in crankshaft
  74
• 4 Pistons and conrods
  77
• 4.1 Assembly overview - pistons and conrods
  77
• 4.2 Removing and installing pistons
  81
• 4.3 Measuring piston projection at TDC
  82
• 4.4 Checking pistons and cylinder bores
  85
• 4.5 Checking radial clearance of conrods
  87
• Cylinder head, valve gear
  88
• 1 Cylinder head
  88
• 1.1 Assembly overview - cylinder head
  88
• 1.2 Assembly overview - cylinder head cover
  92
• 1.3 Removing and installing cylinder head cover
  93
• 1.4 Removing and installing cylinder head
  95
• 1.5 Removing and installing injector seals
  103
• 1.6 Checking compression
  104
• 1.7 Removing and installing camshaft housing
  106
• 2 Toothed belt drive
  111
• 2.1 Assembly overview - toothed belt cover
  111
• 2.2 Assembly overview - toothed belt
  111
• 2.3 Removing and installing toothed belt guard
  113
• 2.4 Removing toothed belt from camshaft
  115
• 2.5 Removing and installing toothed belt
  119
• 3 Valve gear
  134
• 3.1 Assembly overview - valve gear
  134
• 3.2 Measuring axial play of camshaft
  136
• 3.3 Removing and installing camshaft oil seal
  137
• 3.4 Checking hydraulic compensation elements
  139
• 3.5 Removing and installing valve stem seals
  140
• 4 Inlet and exhaust valves
  149
• 4.1 Checking valve guides
  149
• 4.2 Checking valves
  150
• 4.3 Valve dimensions
  150
• Lubrication
  151
• 1 Sump, oil pump
  151
• 1.1 Assembly overview - sump/oil pump
  151
• 1.2 Engine oil:
  153
• 1.3 Removing and installing oil sump
  153
• 1.4 Removing and installing oil pump
  160
• 1.5 Removing and installing oil level and oil temperature sender G266
  164
• 2 Engine oil cooler
  166
• 3 Oil filter, oil pressure switch
  167
• 3.1 Assembly overview - oil filter housing, oil pressure switch
  167
• 3.2 Removing and installing oil pressure switch F1
  168
• 3.3 Checking oil pressure
  169
• 3.4 Removing and installing oil filter housing
  170
• 3.5 Removing and installing oil pressure regulating valve N428
  174
• Cooling
  176
• 1 Cooling system/coolant
  176
• 1.1 Connection diagram - coolant hoses
  176
• 1.2 Checking cooling system for leaks
  177
• 1.3 Draining coolant
  181
• 1.4 Filling with coolant
  182
• 1.5 Checking filling quality of cooling system
  195
• 1.6 Checking electric vacuum pump VAS 6096/2
  197
• 1.7 Flushing cooling system
  198
• 2 Coolant pump, regulation of cooling system
  223
• 2.1 Assembly overview - coolant pump, thermostat
  223
• 2.2 Assembly overview - coolant temperature sender
  225
• 2.3 Assembly overview - electric coolant pump
  226
• 2.4 Removing and installing coolant pump
  227
• 2.5 Removing and installing thermostat
  229
• 2.6 Removing and installing coolant valve for cylinder head N489
  230
• 2.7 Checking thermostat
  231
• 2.8 Removing and installing coolant temperature sender G62
  231
• 2.9 Removing and installing electric coolant pump
  233
• 3 Coolant pipes
  238
• 3.1 Assembly overview - coolant pipes
  238
• 4 Radiator, radiator fan
  239
• 4.1 Assembly overview - radiator/radiator fan
  239
• 4.2 Assembly overview – radiator cowl and radiator fan
  241
• 4.3 Removing and installing radiator
  242
• 4.4 Removing and installing radiator cowl
  248
• 4.5 Removing and installing radiator fan
  249
• Turbocharging/supercharging
  252
• 1 Turbocharger
  252
• 1.1 Assembly overview - turbocharger
  252
• 1.2 Removing and installing turbocharger
  257
• 1.3 Renewing vacuum unit for turbocharger
  265
• 2 Charge air system
  276
• 2.1 Assembly overview - charge air system
  276
• 2.2 Removing and installing charge air cooler
  278
• 2.3 Removing and installing bracket for charge air cooler
  279
• 2.4 Removing and installing charge air temperature sender
  280
• 2.5 Removing and installing charge pressure sender G31
  281
• 2.6 Checking charge air system for leaks
  282
• 2.7 Checking charge air cooler for leaks
  285
• Mixture preparation - injection
  291
• 1 Injection system
  291
• 1.1 Overview of fitting locations - injection system
  291
• 1.2 Schematic overview - fuel system
  295
• 1.3 Filling/bleeding fuel system
  296
• 1.4 Checking fuel system for leaks
  297
• 2 Vacuum system
  298
• 2.1 Connection diagram – vacuum system
  298
• 2.2 Checking vacuum system
  298
• 3 Injectors/high-pressure accumulator (rail)
  300
• 3.1 Assembly overview - injectors
  300
• 3.2 Assembly overview - fuel rail
  302
• 3.3 Removing and installing injectors
  303
• 3.4 Removing and installing high-pressure lines
  308
• 3.5 Testing jammed-open injectors
  311
• 3.6 Checking return flow rate of injectors with engine running
  313
• 3.7 Removing and installing fuel rail
  315
• 4 Air filter
  319
• 4.1 Assembly overview - air filter housing
  319
• 4.2 Removing and installing air filter housing
  321
• 5 Intake manifold
  323
• 5.1 Assembly overview – intake manifold
  323
• 5.2 Removing and installing throttle valve module J338
  323
• 5.3 Removing and installing intake manifold
  325
• 6 Senders and sensors
  331
• 6.1 Removing and installing fuel temperature sender G81
  331
• 6.2 Removing and installing air mass meter G70
  331
• 6.3 Removing and installing fuel pressure regulating valve N276
  333
• 6.4 Removing and installing fuel pressure sender G247
  334
• 6.5 Removing and installing pressure differential sender G505
  336
• 6.6 Removing and installing exhaust gas pressure sensor 1 G450
  337
• 7 Engine control unit
  339
• 7.1 Assembly overview – engine/motor control unit
  339
• 7.2 Removing and installing engine control unit J623
  340
• 7.3 Removing and installing engine (motor) control unit J623 with protective housing
  341
• 8 High-pressure pump
  343
• 8.1 Assembly overview - high-pressure pump
  343
• 8.2 Removing and installing high-pressure pump
  345
• 9 Lambda probe
  351
• 9.1 Assembly overview - Lambda probe
  351
• 9.2 Removing and installing Lambda probe
  352
• Exhaust system
  357
• 1 Exhaust pipes and silencers
  357
• 1.1 Assembly overview – silencers
  357
• 1.2 Separating exhaust pipes from silencers
  358
• 1.3 Removing and installing silencer
  360
• 1.4 Removing and installing front exhaust pipe
  361
• 1.5 Aligning exhaust system free of stress
  363
• 1.6 Installation position of clamp
  364
• 1.7 Align end exhaust pipes
  365
• 1.8 Checking exhaust system for leaks
  365
• 2 Emission control
  366
• 2.1 Assembly overview – emission control
  366
• 2.2 Removing and installing emission control module
  369
• 2.3 Removing and installing particulate filter
  375
• 2.4 Removing and installing exhaust flap control unit J883
  378
• 3 Exhaust gas temperature regulation
  380
• 3.1 Assembly overview – exhaust gas temperature regulation
  380
• 3.2 Removing and installing exhaust gas temperature sender
  382
• 4 Exhaust gas recirculation
  387
• 4.1 Assembly overview – exhaust gas recirculation
  387
• 4.2 Removing and installing exhaust gas recirculation cooler
  393
• 4.3 Removing and installing exhaust gas recirculation control motor V338
  399
• 4.4 Removing and installing exhaust gas recirculation control motor 2 V339
  401
• 4.5 Checking exhaust gas recirculation cooler for leaks
  403
• Glow plug system
  404
• 1 Glow plug system
  404
• 1.1 Assembly overview – glow plug system
  404
• 1.2 Removing and installing glow plug
  405
• 1.3 Removing and installing automatic glow period control unit J179
  409
• 1.4 Removing and installing knock sensor 1 G61
  409
• 1.5 Removing and installing Hall sender G40
  410
• 1.6 Removing and installing engine speed sender G28
  411