4-cyl. common rail (2.0 l, 4V, turbocharger, EA 288 EVO)

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 the 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
  22
• 1.3 Securing engine on engine and gearbox support
  27
• 1.4 Installing engine
  29
• 2 Assembly mountings
  34
• 2.1 Assembly overview – assembly mountings
  34
• 2.2 Removing and installing engine mounting
  36
• 2.3 Removing and installing gearbox mounting
  37
• 2.4 Removing and installing pendulum support
  39
• 2.5 Supporting engine in installation position
  41
• 2.6 Adjusting assembly mountings
  51
• 2.7 Checking adjustment of assembly mountings
  53
• 3 Engine cover panel
  55
• 3.1 Removing and installing engine cover
  55
• Crankshaft group
  56
• 1 Cylinder block (pulley end)
  56
• 1.1 Assembly overview - cylinder block (pulley end)
  56
• 1.2 Assembly overview - sealing flange, belt pulley end
  59
• 1.3 Removing and installing poly-V belt
  60
• 1.4 Removing and installing tensioner for poly V-belt
  61
• 1.5 Removing and installing vibration damper
  62
• 1.6 Removing and installing bracket for ancillaries
  63
• 1.7 Removing and installing engine support
  65
• 1.8 Removing and installing sealing flange on pulley end
  66
• 2 Cylinder block, gearbox end
  71
• 2.1 Assembly overview - cylinder block, gearbox end
  71
• 2.2 Removing and installing flywheel
  74
• 2.3 Removing and installing sealing flange on gearbox side
  75
• 3 Crankshaft
  99
• 3.1 Assembly overview - crankshaft
  99
• 3.2 Crankshaft dimensions
  101
• 3.3 Measuring axial clearance of crankshaft
  101
• 3.4 Renewing needle bearing in crankshaft
  102
• 4 Pistons and conrods
  106
• 4.1 Assembly overview - pistons and conrods
  106
• 4.2 Removing and installing pistons
  111
• 4.3 Measuring piston projection at TDC
  113
• 4.4 Checking pistons and cylinder bores
  115
• 4.5 Checking radial clearance of conrods
  118
• Cylinder head, valve gear
  119
• 1 Cylinder head
  119
• 1.1 Assembly overview - cylinder head
  119
• 1.2 Assembly overview - cylinder head cover
  123
• 1.3 Removing and installing cylinder head
  125
• 1.4 Removing and installing cylinder head cover
  137
• 1.5 Removing and installing injector seals
  138
• 1.6 Removing and installing camshaft housing
  139
• 1.7 Checking compression
  147
• 2 Toothed belt drive
  150
• 2.1 Assembly overview - toothed belt cover
  150
• 2.2 Assembly overview - toothed belt
  151
• 2.3 Removing and installing toothed belt guard
  153
• 2.4 Removing and installing toothed belt
  157
• 2.5 Removing toothed belt from camshaft
  170
• 3 Valve gear
  180
• 3.1 Assembly overview - valve gear
  180
• 3.2 Measuring axial play of camshaft
  182
• 3.3 Removing and installing camshaft oil seal
  183
• 3.4 Checking hydraulic compensation elements
  185
• 3.5 Removing and installing valve stem seals
  186
• 4 Inlet and exhaust valves
  203
• 4.1 Checking valve guides
  203
• 4.2 Checking valves
  204
• 4.3 Valve dimensions
  204
• Lubrication
  206
• 1 Sump, oil pump
  206
• 1.1 Assembly overview - sump/oil pump
  206
• 1.2 Engine oil:
  210
• 1.3 Removing and installing lower part of sump
  210
• 1.4 Removing and installing upper part of sump
  215
• 1.5 Removing and installing oil pump
  219
• 1.6 Removing and installing oil level and oil temperature sender G266
  219
• 2 Engine oil cooler
  221
• 3 Oil filter, oil pressure switch
  222
• 3.1 Assembly overview - oil filter housing, oil pressure switch
  222
• 3.2 Assembly overview - oil pressure switches/oil pressure control
  224
• 3.3 Removing and installing oil pressure sender G10
  225
• 3.4 Checking oil pressure
  226
• 3.5 Removing and installing oil filter housing
  227
• 3.6 Removing and installing oil pressure regulating valve N428
  229
• 3.7 Removing and installing piston cooling jet control valve N522
  230
• 4 Oil circuit
  231
• 4.1 Removing and installing oil supply line
  231
• 4.2 Removing and installing oil return line for turbocharger
  232
• Cooling
  234
• 1 Cooling system/coolant
  234
• 1.1 Connection diagram - coolant hoses
  234
• 1.2 Checking cooling system for leaks
  236
• 1.3 Draining coolant
  239
• 1.4 Filling with coolant
  241
• 1.5 Checking filling quality of cooling system
  260
• 1.6 Checking electric vacuum pump VAS 6096/2
  262
• 1.7 Flushing cooling system
  263
• 2 Coolant pump, regulation of cooling system
  285
• 2.1 Assembly overview - coolant pump, thermostat
  285
• 2.2 Assembly overview - electric coolant pump
  288
• 2.3 Assembly overview - coolant temperature sender
  290
• 2.4 Removing and installing electric coolant pump
  292
• 2.5 Removing and installing coolant pump
  300
• 2.6 Removing and installing coolant distribution module
  302
• 2.7 Removing and installing coolant regulating valve N515
  304
• 2.8 Removing and installing coolant temperature sender G62
  306
• 2.9 Removing and installing engine outlet coolant temperature sender G82
  308
• 2.10 Removing and installing coolant temperature sender for charge air cooler G1130
  310
• 3 Coolant pipes
  313
• 3.1 Assembly overview - coolant pipes
  313
• 3.2 Removing and installing coolant pipes
  314
• 4 Radiator, radiator fan
  322
• 4.1 Assembly overview - radiator/radiator fan
  322
• 4.2 Assembly overview – radiator cowl and radiator fan
  325
• 4.3 Removing and installing radiator
  326
• 4.4 Removing and installing water radiator for charge air cooling circuit
  328
• 4.5 Removing and installing radiator cowl
  334
• 4.6 Removing and installing radiator fan
  335
• Turbocharging/supercharging
  337
• 1 Turbocharger
  337
• 1.1 Assembly overview - turbocharger
  337
• 1.2 Removing and installing turbocharger
  340
• 1.3 Removing and installing connection for turbocharger
  345
• 2 Charge air system
  347
• 2.1 Assembly overview - charge air system
  347
• 2.2 Removing and installing charge pressure sender GX26
  347
• 2.3 Checking charge air system for leaks
  347
• 2.4 Removing and installing air pipe
  350
• 2.5 Checking charge air cooler for leaks
  351
• Mixture preparation - injection
  357
• 1 Injection system
  357
• 1.1 Schematic overview - fuel system
  357
• 1.2 Overview of fitting locations - injection system
  359
• 1.3 Filling/bleeding fuel system
  371
• 1.4 Checking fuel system for leaks
  371
• 2 Injectors/high-pressure accumulator (rail)
  373
• 2.1 Assembly overview - injectors
  373
• 2.2 Assembly overview - fuel rail
  375
• 2.3 Adapting correction values for injectors
  376
• 2.4 Testing injectors
  377
• 2.5 Checking return flow rate of injectors with engine running
  378
• 2.6 Checking return flow rate of injectors at starter speed
  381
• 2.7 Testing jammed-open injectors
  383
• 2.8 Removing and installing injectors
  385
• 2.9 Removing and installing high-pressure lines
  389
• 2.10 Removing and installing fuel rail
  394
• 3 Air filter
  399
• 3.1 Assembly overview - air filter housing
  399
• 3.2 Removing and installing air filter housing
  401
• 3.3 Removing and installing air guide on lock carrier
  403
• 4 Intake manifold
  405
• 4.1 Assembly overview – intake manifold
  405
• 4.2 Removing and installing intake manifold
  410
• 4.3 Removing and installing throttle valve module GX3
  417
• 5 Senders and sensors
  420
• 5.1 Removing and installing fuel pressure regulating valve N276
  420
• 5.2 Checking fuel pressure regulating valve N276
  422
• 5.3 Removing and installing fuel pressure sender G247
  423
• 5.4 Removing and installing air mass measurement module GX35
  425
• 5.5 Removing and installing pressure differential sender G505
  427
• 5.6 Removing and installing NOx sender 2 G687
  429
• 5.7 Removing and installing NOx sender 3 G932
  430
• 5.10 Removing and installing NOx sender G295
  433
• 5.11 Removing and installing particle sensor G784
  435
• 6 Engine control unit
  439
• 6.1 Removing and installing engine control unit J623
  439
• 6.2 Removing and installing engine control unit J623 (with protective housing)
  440
• 7 High-pressure pump
  447
• 7.1 Assembly overview - high-pressure pump
  447
• 7.2 Removing and installing high-pressure pump
  447
• 8 Lambda probe
  452
• 8.1 Assembly overview - Lambda probe
  452
• 8.2 Removing and installing Lambda probe
  453
• Exhaust system
  455
• 1 Exhaust pipes and silencers
  455
• 1.1 Assembly overview – silencers
  455
• 1.2 Assembly overview - front exhaust pipe
  456
• 1.3 Separating exhaust pipes from silencers
  460
• 1.4 Removing and installing silencer
  461
• 1.5 Aligning exhaust system free of stress
  462
• 1.6 Checking exhaust system for leaks
  462
• 1.7 Installation position of clamp
  463
• 1.8 Align end exhaust pipes
  464
• 2 Emission control
  465
• 2.1 Assembly overview – emission control
  465
• 2.2 Removing and installing emission control module
  467
• 2.3 Removing and installing exhaust flap control unit J883
  475
• 2.4 Removing and installing ammonia traps
  477
• 3 SCR system (selective catalytic reduction)
  480
• 3.1 Overview of fitting locations – SCR system (selective catalytic reduction)
  480
• 3.2 Assembly overview - tank for reducing agent
  486
• 3.3 Assembly overview – filler tube for reducing agent tank
  494
• 3.4 Assembly overview - reducing agent supply line
  498
• 3.5 Assembly overview - delivery unit for reducing agent metering system GX19
  508
• 3.6 Removing and installing reducing agent tank
  509
• 3.7 Removing and installing front section of reducing agent supply line
  522
• 3.9 Removing and installing injector for reduction agent N474
  528
• 3.10 Removing and installing injector 2 for reducing agent N758
  531
• 3.11 Removing and installing control unit for reducing-agent heater J891
  533
• 3.12 Assembly overview - injector for reducing agent N474
  544
• 3.13 Assembly overview – injector 2 for reducing agent N758
  545
• 3.14 Draining reducing agent tank
  546
• 3.15 Removing and installing middle section of reducing agent supply line
  550
• 3.16 Removing and installing rear section of reducing agent supply line
  551
• 3.17 Removing and installing filler pipe for reducing agent tank
  559
• 3.18 Disconnecting reducing agent supply line
  568
• 3.19 SCR - resetting learnt values
  573
• 4 Exhaust gas temperature regulation
  575
• 4.1 Assembly overview – exhaust gas temperature regulation
  575
• 4.2 Removing and installing exhaust gas temperature sender 1 G235
  576
• 4.3 Removing and installing exhaust gas temperature sender 2 G448
  578
• 4.4 Removing and installing exhaust gas temperature sender 3 G495
  580
• 4.5 Removing and installing exhaust gas temperature sender 4 G648
  582
• 5 Exhaust gas recirculation
  586
• 5.1 Assembly overview – exhaust gas recirculation
  586
• 5.2 Removing and installing exhaust gas recirculation cooler
  589
• 5.3 Removing and installing exhaust gas recirculation valve 1 GX5
  592
• 5.4 Removing and installing exhaust gas recirculation valve 2 GX6
  593
• 5.5 Removing and installing exhaust gas recirculation temperature sensor G98
  594
• 5.6 Checking exhaust gas recirculation cooler for leaks
  595
• Glow plug system
  601
• 1 Glow plug system
  601
• 1.1 Assembly overview - glow plug system
  601
• 1.2 Removing and installing glow plug
  603
• 1.3 Removing and installing automatic glow period control unit J179
  607
• 1.4 Removing and installing Hall sender G40
  608
• 1.5 Removing and installing engine speed sender G28
  608