4-cyl. common rail (2.0 l, 4V, turbocharger, EA288, emission control module)

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 a start/stop system
  2
• 1.4 Safety precautions when working on the cooling system
  2
• 1.5 Safety precautions when working on SCR system
  3
• 1.6 Safety precautions when working on ignition system
  3
• 1.7 Safety precautions when working on exhaust system
  4
• 2 Identification
  5
• 2.1 Engine number/engine data
  5
• 3 Repair instructions
  7
• 3.1 Rules for cleanliness
  7
• 3.2 General notes
  7
• 3.3 General repair notes
  8
• 3.4 Foreign objects in engine
  8
• 3.5 Contact corrosion
  8
• 3.6 Routing and attachment of lines
  9
• 3.7 Fitting radiator and condensers
  9
• 3.8 Checking vacuum system
  9
• Removing and installing engine
  10
• 1 Removing and installing engine
  10
• 1.1 Removing engine
  10
• 1.2 Separating engine and gearbox
  19
• 1.3 Securing engine on engine and gearbox support
  21
• 1.4 Installing engine
  23
• 2 Assembly mountings
  27
• 2.1 Assembly overview - assembly mountings
  27
• 2.2 Removing and installing engine mounting
  34
• 2.3 Removing and installing engine mounting
  40
• 2.4 Removing and installing gearbox mounting
  40
• 2.5 Removing and installing damper weight
  41
• 2.6 Supporting engine in installation position
  42
• 3 Engine cover panel
  46
• 3.1 Assembly overview – engine compartment cover
  46
• 3.2 Removing and installing engine compartment cover
  46
• Crankshaft group
  48
• 1 Cylinder block (pulley end)
  48
• 1.1 Assembly overview - cylinder block (pulley end)
  48
• 1.2 Assembly overview - sealing flange, belt pulley end
  51
• 1.3 Removing and installing poly-V belt
  52
• 1.4 Removing and installing tensioner for poly V-belt
  56
• 1.5 Removing and installing vibration damper
  57
• 1.6 Removing and installing bracket for ancillaries
  60
• 1.7 Removing and installing engine support
  62
• 1.8 Removing and installing sealing flange on pulley end
  68
• 1.9 Renewing caps in cylinder block (pulley end)
  71
• 2 Cylinder block, gearbox end
  73
• 2.1 Assembly overview - cylinder block, gearbox end
  73
• 2.2 Removing and installing flywheel
  76
• 2.3 Removing and installing sealing flange on gearbox side
  78
• 2.4 Renewing caps in cylinder block (gearbox end)
  88
• 3 Crankshaft
  91
• 3.1 Assembly overview - crankshaft
  91
• 3.2 Crankshaft dimensions
  93
• 3.3 Renewing needle bearing in crankshaft
  93
• 3.4 Measuring axial clearance of crankshaft
  95
• 3.5 Measuring radial clearance of crankshaft
  96
• 4 Pistons and conrods
  97
• 4.1 Assembly overview - pistons and conrods
  97
• 4.2 Removing and installing pistons
  100
• 4.3 Measuring piston projection at TDC
  101
• 4.4 Checking pistons and cylinder bores
  103
• 4.5 Separating new conrod
  106
• 4.6 Checking radial clearance of conrods
  106
• 4.7 Removing and installing oil spray jets
  107
• Cylinder head, valve gear
  109
• 1 Cylinder head
  109
• 1.1 Assembly overview - cylinder head
  109
• 1.2 Assembly overview - camshaft housing
  112
• 1.3 Assembly overview - cylinder head cover
  114
• 1.4 Removing and installing cylinder head
  117
• 1.5 Removing and installing cylinder head cover
  125
• 1.6 Removing and installing injector seals
  126
• 1.7 Removing and installing camshaft housing
  128
• 1.8 Checking compression
  133
• 1.9 Checking combustion chamber for leaks
  135
• 2 Toothed belt drive
  137
• 2.1 Assembly overview - toothed belt cover
  137
• 2.2 Assembly overview - toothed belt
  137
• 2.3 Removing and installing toothed belt guard
  139
• 2.4 Removing and installing toothed belt
  142
• 2.5 Removing toothed belt from camshaft
  158
• 3 Valve gear
  165
• 3.1 Assembly overview - valve gear
  165
• 3.2 Measuring axial play of camshaft
  167
• 3.3 Removing and installing camshaft oil seal
  168
• 3.4 Checking hydraulic compensation elements
  170
• 3.5 Removing and installing valve stem seals
  171
• 4 Inlet and exhaust valves
  188
• 4.1 Checking valve guides
  188
• 4.2 Checking valves
  189
• 4.3 Valve dimensions
  189
• Lubrication
  191
• 1 Sump, oil pump
  191
• 1.1 Assembly overview - sump/oil pump
  191
• 1.2 Assembly overview - oil pump drive pulley
  194
• 1.3 Engine oil:
  195
• 1.4 Removing and installing oil sump
  195
• 1.5 Removing and installing oil pump
  201
• 1.6 Removing and installing oil level and oil temperature sender G266
  202
• 1.7 Removing and installing sump trim
  202
• 1.8 Removing and installing oil pump drive pulley
  203
• 2 Engine oil cooler
  208
• 3 Oil filter, oil pressure switch
  209
• 3.1 Assembly overview - oil filter housing, oil pressure switch
  209
• 3.2 Removing and installing oil pressure sender G10
  211
• 3.3 Checking oil pressure
  212
• 3.4 Removing and installing oil filter housing
  213
• 3.5 Removing and installing oil pressure regulating valve N428
  215
• 4 Oil circuit
  216
• 4.1 Assembly overview - oil circuit
  216
• 4.2 Removing and installing oil supply lines
  219
• 4.3 Removing and installing oil return line for turbocharger
  222
• Cooling
  226
• 1 Cooling system/coolant
  226
• 1.1 Connection diagram - coolant hoses
  226
• 1.2 Draining and adding coolant
  250
• 1.3 Checking coolant level and topping up
  261
• 1.4 Checking cooling system for leaks
  262
• 1.5 Removing and installing coolant expansion tank
  265
• 1.6 Assembly overview – coolant expansion tank
  268
• 2 Coolant pump, regulation of cooling system
  270
• 2.1 Assembly overview - coolant pump, thermostat
  270
• 2.2 Assembly overview - electric coolant pump
  271
• 2.3 Assembly overview - coolant temperature sender
  276
• 2.4 Assembly overview – mixing valve for coolant regulation GX40
  278
• 2.5 Assembly overview – 3/2-way valve
  279
• 2.6 Assembly overview – thermostat
  281
• 2.7 Removing and installing electric coolant pump
  282
• 2.8 Removing and installing coolant pump
  287
• 2.9 Removing and installing thermostat
  288
• 2.10 Removing and installing mixing valve for coolant regulation GX40
  289
• 2.11 Removing and installing thermostat
  291
• 2.12 Removing and installing coolant temperature sender G62
  292
• 2.13 Removing and installing radiator outlet coolant temperature sender G83
  293
• 2.14 Removing and installing coolant temperature sender 2 G802
  294
• 2.15 Removing and installing coolant temperature sender for charge air cooler G1130
  295
• 2.16 Removing and installing coolant temperature sender 3 G812
  296
• 2.17 Removing and installing 3/2-way valve
  297
• 2.18 Removing and installing front shut-off flap
  300
• 3 Coolant pipes
  302
• 3.1 Assembly overview - coolant pipes
  302
• 3.2 Removing and installing coolant pipes
  307
• 4 Radiator, radiator fan
  309
• 4.1 Assembly overview - radiator/radiator fan
  309
• 4.2 Assembly overview – radiator cowl and radiator fan
  312
• 4.3 Removing and installing radiator
  312
• 4.4 Removing and installing radiator cowl with radiator fan
  321
• 4.5 Removing and installing radiator fan V7
  322
• Turbocharging/supercharging
  323
• 1 Turbocharger
  323
• 1.1 Assembly overview - turbocharger
  323
• 1.2 Assembly overview - vacuum unit and charge pressure positioner V465, biturbo
  329
• 1.3 Removing and installing turbocharger
  331
• 1.4 Checking vacuum unit for turbocharger, biturbo
  340
• 1.5 Removing and installing connecting pipes
  350
• 1.6 Removing and installing compressor housing and turbine housing, biturbo
  353
• 2 Charge air system
  355
• 2.1 Assembly overview - charge air system
  355
• 2.2 Removing and installing charge air cooler
  359
• 2.3 Removing and installing charge pressure sender G31
  362
• 2.4 Removing and installing charge pressure sender 2 G447
  363
• 2.5 Checking charge air system for leaks
  363
• 2.6 Detaching and securing charge air cooler
  366
• 2.7 Removing and installing bracket for charge air cooler
  368
• 2.8 Checking charge air cooler for leaks
  371
• Mixture preparation - injection
  375
• 1 Injection system
  375
• 1.1 Overview of fitting locations - injection system
  375
• 1.2 Filling/bleeding fuel system
  389
• 1.3 Checking fuel system for leaks
  390
• 2 Vacuum system
  391
• 2.1 Connection diagram – vacuum system
  391
• 2.2 Assembly overview – vacuum system
  393
• 2.3 Assembly overview – valves for vacuum system
  396
• 2.4 Removing and installing solenoid valve N274/N529
  398
• 3 Injectors/high-pressure accumulator (rail)
  399
• 3.1 Assembly overview - injectors
  399
• 3.2 Assembly overview - fuel rail
  401
• 3.3 Adapting correction values for injectors
  402
• 3.4 Testing injectors
  404
• 3.5 Testing jammed-open injectors
  404
• 3.6 Checking return flow rate of injectors with engine running
  406
• 3.7 Checking return flow rate of injectors at starter speed
  409
• 3.8 Removing and installing injectors
  410
• 3.9 Removing and installing high-pressure lines
  415
• 3.10 Removing and installing fuel rail
  420
• 4 Air filter
  423
• 4.1 Assembly overview - air filter housing
  423
• 4.2 Removing and installing air filter housing
  427
• 5 Intake manifold
  430
• 5.1 Assembly overview – intake manifold
  430
• 5.2 Removing and installing intake manifold
  432
• 5.3 Removing and installing throttle valve module GX3
  436
• 5.4 Removing and installing intake manifold flap valve N316
  436
• 6 Senders and sensors
  439
• 6.1 Removing and installing fuel pressure regulating valve N276
  439
• 6.2 Checking fuel pressure regulating valve N276
  441
• 6.3 Removing and installing fuel pressure sender G247
  442
• 6.4 Removing and installing air mass meter G70
  445
• 6.5 Removing and installing pressure differential sender G505
  446
• 6.10 Removing and installing NOx sender G295
  452
• 6.11 Removing and installing NOx sender 2 G687
  452
• 6.12 Removing and installing NOx sender 3 G932
  454
• 6.13 Overview of fitting locations - exhaust gas sensors
  456
• 7 Engine control unit
  457
• 7.1 Removing and installing engine control unit J623
  457
• 8 High-pressure pump
  459
• 8.1 Assembly overview - high-pressure pump
  459
• 8.2 Removing and installing high-pressure pump
  461
• 8.3 Checking high-pressure pump
  465
• 9 Lambda probe
  468
• 9.1 Assembly overview - Lambda probe
  468
• 9.2 Removing and installing Lambda probe GX10
  469
• Exhaust system
  472
• 1 Exhaust pipes and silencers
  472
• 1.1 Assembly overview – silencers
  472
• 1.2 Assembly overview - front exhaust pipe
  473
• 1.3 Removing and installing front exhaust pipe
  475
• 1.4 Separating exhaust pipes from silencers
  476
• 1.5 Removing and installing front silencer
  478
• 1.6 Removing and installing rear silencer
  479
• 1.7 Aligning exhaust system free of stress
  480
• 1.8 Checking exhaust system for leaks
  481
• 1.9 Installation position of clamp
  482
• 2 Emission control
  483
• 2.1 Assembly overview – emission control
  483
• 2.2 Removing and installing emission control module
  489
• 2.3 Removing and installing exhaust flap control unit J883
  495
• 3 SCR system (selective catalytic reduction)
  498
• 3.1 Assembly overview – reducing agent tank
  498
• 3.2 Assembly overview - delivery module for reducing agent
  500
• 3.3 Assembly overview – filler tube for reducing agent tank
  500
• 3.4 Assembly overview - injector for reducing agent N474
  501
• 3.5 Assembly overview – injector 2 for reducing agent N758
  502
• 3.6 Removing and installing reducing agent tank VX85
  503
• 3.7 Removing and installing reducing agent supply line
  506
• 3.8 Removing and installing delivery unit for reducing agent metering system GX19
  510
• 3.9 Removing and installing injector for reduction agent N474
  513
• 3.10 Removing and installing injector 2 for reducing agent N758
  516
• 3.11 Removing and installing control unit for reducing-agent heater J891
  517
• 3.12 Draining reducing agent tank VX85
  517
• 3.13 Removing and installing filler pipe for tank for reducing agent
  521
• 4 Exhaust gas temperature regulation
  522
• 4.1 Assembly overview – exhaust gas temperature regulation
  522
• 4.2 Removing and installing exhaust gas temperature sender 1 G235
  525
• 4.3 Removing and installing exhaust gas temperature sender 2 G448
  530
• 4.4 Removing and installing exhaust gas temperature sender 3 G495
  535
• 4.5 Removing and installing exhaust gas temperature sender 4 G648
  537
• 5 Exhaust gas recirculation
  539
• 5.1 Assembly overview – exhaust gas recirculation
  539
• 5.2 Removing and installing exhaust gas recirculation cooler
  544
• 5.3 Removing and installing exhaust gas recirculation pipes
  549
• 5.4 Removing and installing exhaust gas recirculation temperature sensor G98
  552
• 5.5 Removing and installing exhaust gas recirculation valve
  553
• 6 Heat insulation mats
  555
• 6.1 Assembly overview – heat insulation mats
  555
• 6.2 Heat insulation mat, emission control module
  555
• Glow plug system
  563
• 1 Glow plug system
  563
• 1.1 Assembly overview – glow plug system
  563
• 1.2 Removing and installing glow plug
  564
• 1.3 Checking glow plug
  569
• 1.4 Removing and installing automatic glow period control unit J179
  570
• 1.5 Removing and installing inlet camshaft position sender G1002
  570
• 1.6 Removing and installing engine speed sender G28
  571