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 SCR system
  2
• 1.6 Safety precautions when working on exhaust system
  3
• 2 Identification
  4
• 2.1 Engine number/engine data
  4
• 3 Repair instructions
  5
• 3.1 Rules for cleanliness
  5
• 3.2 Foreign objects in engine
  5
• 3.3 Contact corrosion
  5
• 3.4 Routing and attachment of lines
  6
• 3.5 Checking vacuum system
  6
• Removing and installing engine
  7
• 1 Removing and installing engine
  7
• 1.1 Removing engine
  7
• 1.2 Separating engine and gearbox
  16
• 1.3 Securing engine on engine and gearbox support
  20
• 1.4 Installing engine
  21
• 2 Assembly mountings
  25
• 2.1 Assembly overview - assembly mountings
  25
• 2.2 Removing and installing engine mounting
  27
• 2.3 Removing and installing gearbox mounting
  28
• 2.4 Removing and installing pendulum support
  29
• 2.5 Supporting engine in installation position
  30
• 2.6 Adjusting assembly mountings
  35
• 2.7 Checking adjustment of assembly mountings
  37
• 3 Engine cover panel
  39
• 3.1 Removing and installing engine cover
  39
• Crankshaft group
  40
• 1 Cylinder block (pulley end)
  40
• 1.1 Assembly overview - cylinder block (pulley end)
  40
• 1.2 Assembly overview - sealing flange, belt pulley end
  43
• 1.3 Removing and installing poly-V belt
  45
• 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
  50
• 2 Cylinder block, gearbox end
  53
• 2.1 Assembly overview - cylinder block, gearbox end
  53
• 2.2 Removing and installing flywheel
  55
• 2.3 Removing and installing sealing flange on gearbox side
  56
• 2.4 Removing and installing adapter plate
  79
• 2.5 Removing and installing intermediate plate
  80
• 3 Crankshaft
  81
• 3.1 Assembly overview - crankshaft
  81
• 3.2 Crankshaft dimensions
  83
• 3.3 Renewing needle bearing in crankshaft
  83
• 3.4 Measuring axial clearance of crankshaft
  85
• 3.5 Measuring radial clearance of crankshaft
  86
• 4 Pistons and conrods
  87
• 4.1 Assembly overview - pistons and conrods
  87
• 4.2 Removing and installing pistons
  90
• 4.3 Measuring piston projection at TDC
  92
• 4.4 Checking pistons and cylinder bores
  94
• 4.5 Separating new conrod
  97
• 4.6 Checking radial clearance of conrods
  97
• 4.7 Removing and installing oil spray jets
  98
• Cylinder head, valve gear
  99
• 1 Cylinder head
  99
• 1.1 Assembly overview - cylinder head
  99
• 1.2 Assembly overview - camshaft housing
  101
• 1.3 Assembly overview - cylinder head cover
  103
• 1.4 Removing and installing cylinder head
  105
• 1.5 Removing and installing cylinder head cover
  111
• 1.6 Removing and installing injector seals
  112
• 1.7 Removing and installing camshaft housing
  113
• 1.8 Checking compression
  118
• 2 Toothed belt drive
  121
• 2.1 Assembly overview - toothed belt cover
  121
• 2.2 Assembly overview - toothed belt
  121
• 2.3 Removing and installing toothed belt guard
  123
• 2.4 Removing and installing toothed belt
  128
• 2.5 Removing toothed belt from camshaft
  136
• 3 Valve gear
  144
• 3.1 Assembly overview - valve gear
  144
• 3.2 Measuring axial play of camshaft
  146
• 3.3 Removing and installing camshaft oil seal
  147
• 3.4 Checking hydraulic compensation elements
  149
• 3.5 Removing and installing valve stem seals
  150
• 3.6 Removing and installing toothed belt pulley
  158
• 4 Inlet and exhaust valves
  160
• 4.1 Checking valve guides
  160
• 4.2 Checking valves
  161
• 4.3 Valve dimensions
  161
• Lubrication
  162
• 1 Sump, oil pump
  162
• 1.1 Assembly overview - sump/oil pump
  162
• 1.2 Engine oil:
  165
• 1.3 Removing and installing lower part of sump
  165
• 1.4 Removing and installing upper part of sump
  168
• 1.5 Removing and installing oil pump
  171
• 1.6 Removing and installing oil level and oil temperature sender G266
  171
• 1.7 Removing and installing toothed belt for oil pump
  173
• 2 Engine oil cooler
  174
• 3 Oil filter, oil pressure switch
  175
• 3.1 Assembly overview - oil filter housing, oil pressure switch
  175
• 3.2 Assembly overview - oil pressure switches/oil pressure control
  177
• 3.3 Checking oil pressure
  178
• 3.4 Removing and installing oil filter housing
  178
• 3.5 Removing and installing oil pressure regulating valve N428
  179
• 3.6 Removing and installing oil pressure sender G10
  180
• 3.7 Removing and installing piston cooling jet control valve N522
  182
• 4 Oil circuit
  184
• 4.1 Assembly overview - oil circuit
  184
• 4.2 Removing and installing oil supply line
  184
• 4.3 Removing and installing oil return line for turbocharger
  186
• Cooling
  188
• 1 Cooling system/coolant
  188
• 1.1 Checking cooling system for leaks
  188
• 1.2 Draining and adding coolant
  190
• 1.3 Checking filling quality
  204
• 2 Coolant pump, regulation of cooling system
  207
• 2.1 Assembly overview - coolant pump, thermostat
  207
• 2.2 Assembly overview - electric coolant pump
  209
• 2.3 Assembly overview - coolant temperature sender
  210
• 2.4 Removing and installing coolant pump
  211
• 2.5 Removing and installing thermostat
  212
• 2.6 Removing and installing coolant temperature sender G62
  214
• 2.7 Removing and installing engine outlet coolant temperature sender G82
  214
• 2.8 Removing and installing coolant regulating valve N515
  215
• 2.9 Removing and installing auxiliary pump for heating V488
  216
• 2.10 Removing and installing charge air cooling pump V188
  218
• 2.11 Removing and installing coolant temperature sender for charge air cooler G1130
  220
• 3 Coolant pipes
  222
• 3.1 Assembly overview - coolant pipes
  222
• 3.2 Removing and installing coolant pipes
  222
• 4 Radiator, radiator fan
  227
• 4.1 Assembly overview - radiator, radiator fan
  227
• 4.2 Assembly overview – radiator cowl and radiator fan
  229
• 4.3 Removing and installing radiator
  229
• 4.4 Removing and installing cooler for charge air cooling circuit
  231
• 4.5 Removing and installing radiator cowl
  234
• 4.6 Removing and installing radiator fan VX57
  235
• 4.7 Removing and installing radiator fan 2 V177
  236
• Turbocharging/supercharging
  238
• 1 Turbocharger
  238
• 1.1 Assembly overview - turbocharger
  238
• 1.2 Removing and installing turbocharger
  241
• 1.3 Removing and installing connection for turbocharger
  243
• 2 Charge air system
  245
• 2.1 Assembly overview - charge air system
  245
• 2.2 Checking charge air cooler for leaks
  245
• 2.3 Removing and installing charge air cooler
  249
• 2.4 Removing and installing charge pressure sender GX26
  249
• 2.5 Checking charge air system for leaks
  250
• 2.6 Removing and installing air intake pipe
  253
• Mixture preparation - injection
  255
• 1 Injection system
  255
• 1.1 Filling/bleeding fuel system
  255
• 1.2 Checking fuel system for leaks
  255
• 2 Injectors/high-pressure accumulator (rail)
  257
• 2.1 Assembly overview - injectors
  257
• 2.2 Assembly overview - fuel rail
  258
• 2.3 Adapting correction values for injectors
  260
• 2.4 Testing injectors
  261
• 2.5 Checking return flow rate of injectors with engine running
  261
• 2.6 Checking return flow rate of injectors at starter speed
  264
• 2.7 Testing jammed-open injectors
  266
• 2.8 Removing and installing injectors
  268
• 2.9 Removing and installing high-pressure lines
  271
• 2.10 Removing and installing fuel rail
  276
• 3 Air filter
  279
• 3.1 Assembly overview - air filter housing
  279
• 3.2 Removing and installing air filter housing
  281
• 3.3 Removing and installing air guide on lock carrier
  281
• 4 Intake manifold
  283
• 4.1 Assembly overview – intake manifold
  283
• 4.2 Removing and installing intake manifold
  287
• 4.3 Removing and installing throttle valve module GX3
  290
• 5 Senders and sensors
  293
• 5.1 Removing and installing fuel pressure regulating valve N276
  293
• 5.2 Checking fuel pressure regulating valve N276
  295
• 5.3 Removing and installing fuel pressure sender G247
  297
• 5.4 Removing and installing pressure differential sender G505
  298
• 5.7 Removing and installing control unit for NOx sender GX30
  301
• 5.8 Removing and installing air mass measurement module GX35
  302
• 5.9 Removing and installing control unit 2 for NOx sender GX46
  304
• 5.10 Removing and installing control unit 3 for NOx sender GX50
  306
• 5.11 Removing and installing control unit 1 for particulate sensor GX52
  307
• 6 Engine control unit
  310
• 6.1 Removing and installing engine control unit J623
  310
• 7 High-pressure pump
  312
• 7.1 Assembly overview - high-pressure pump
  312
• 7.2 Removing and installing high-pressure pump
  312
• 8 Lambda probe
  318
• 8.1 Assembly overview - Lambda probe
  318
• 8.2 Removing and installing Lambda probe 1 before catalytic converter GX10
  320
• Exhaust system
  322
• 1 Exhaust pipes and silencers
  322
• 1.1 Assembly overview – silencers
  322
• 1.2 Assembly overview - front exhaust pipe
  324
• 1.3 Removing and installing front exhaust pipe
  326
• 1.4 Separating exhaust pipes from silencers
  328
• 1.5 Removing and installing silencer
  329
• 1.6 Renewing exhaust pipes
  333
• 1.7 Aligning exhaust system free of stress
  333
• 1.8 Checking exhaust system for leaks
  334
• 1.9 Installation position of clamp
  335
• 2 Emission control
  336
• 2.1 Assembly overview – emission control
  336
• 2.2 Removing and installing emission control module
  338
• 2.3 Removing and installing exhaust flap control unit J883
  344
• 3 SCR system (selective catalytic reduction)
  347
• 3.1 Assembly overview – reducing agent tank
  347
• 3.2 Assembly overview - reducing agent supply line
  348
• 3.3 Assembly overview - delivery module for reducing agent
  349
• 3.4 Removing and installing reducing agent tank
  350
• 3.5 Removing and installing filler pipe for reducing agent tank
  352
• 3.6 Removing and installing front section of reducing agent supply line
  354
• 3.7 Removing and installing middle section of reducing agent supply line
  358
• 3.8 Removing and installing rear section of reducing agent supply line
  360
• 3.9 Removing and installing delivery unit for reducing agent metering system GX19
  362
• 3.10 Removing and installing injector for reduction agent N474
  363
• 3.11 Removing and installing control unit for reducing-agent heater J891
  366
• 3.12 Draining reducing agent tank
  366
• 3.13 SCR - resetting learnt values
  368
• 3.14 Removing and installing injector 2 for reducing agent N758
  368
• 4 Exhaust gas temperature regulation
  371
• 4.1 Assembly overview – exhaust gas temperature regulation
  371
• 4.2 Removing and installing exhaust gas temperature sender 1 G235
  372
• 4.3 Removing and installing exhaust gas temperature sender 2 G448
  374
• 4.4 Removing and installing exhaust gas temperature sender 3 G495
  375
• 4.5 Removing and installing exhaust gas temperature sender 4 G648
  377
• 5 Exhaust gas recirculation
  380
• 5.1 Assembly overview – exhaust gas recirculation
  380
• 5.2 Removing and installing exhaust gas recirculation cooler
  381
• 5.3 Checking exhaust gas recirculation cooler for leaks
  383
• 5.4 Removing and installing exhaust gas recirculation valve 1 GX5
  387
• 5.5 Removing and installing exhaust gas recirculation valve 2 GX6
  388
• 5.6 Removing and installing exhaust gas recirculation temperature sensor G98
  389
• Glow plug system
  392
• 1 Glow plug system
  392
• 1.1 Assembly overview – glow plug system
  392
• 1.2 Removing and installing glow plug
  393
• 1.3 Removing and installing automatic glow period control unit J179
  396
• 1.4 Removing and installing Hall sender G40
  396
• 1.5 Removing and installing engine speed sender G28
  397