4-cyl. common rail (2.0 l, 4V, turbocharger, inline engine)

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
  2
• 1.5 Safety precautions when working on the SCR system
  2
• 1.6 Safety precautions when working on ignition system
  3
• 1.7 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 General information
  5
• 3.3 Foreign objects in engine
  6
• 3.4 Contact corrosion
  6
• 3.5 Routing and attachment of lines
  6
• 3.6 Checking vacuum system
  6
• Removing and installing engine
  8
• 1 Removing and installing motor
  8
• 1.1 Removing motor
  8
• 1.2 Separating engine and gearbox
  16
• 1.3 Securing engine on engine and gearbox support
  17
• 1.4 Installing engine
  19
• 2 Assembly mountings
  23
• 2.1 Assembly overview - assembly mountings
  23
• 2.2 Removing and installing engine mounting
  25
• 2.3 Removing and installing gearbox mountings
  27
• 2.4 Removing and installing engine mounting
  28
• 2.5 Supporting engine in installation position
  30
• Crankshaft group
  35
• 1 Cylinder block (pulley end)
  35
• 1.1 Assembly overview - cylinder block (pulley end)
  35
• 1.2 Assembly overview - sealing flange, belt pulley end
  37
• 1.3 Removing and installing poly-V belt
  39
• 1.4 Removing and installing tensioner for poly V-belt
  43
• 1.5 Removing and installing vibration damper
  44
• 1.6 Removing and installing bracket for ancillaries
  46
• 1.7 Removing and installing engine support
  48
• 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 Assembly overview - drive plate
  56
• 2.3 Removing and installing drive plate
  57
• 2.4 Removing and installing flywheel
  58
• 2.5 Removing and installing sealing flange on gearbox side
  60
• 3 Crankshaft
  70
• 3.1 Assembly overview - crankshaft
  70
• 3.2 Crankshaft dimensions
  72
• 3.3 Renewing needle bearing in crankshaft
  72
• 3.4 Measuring axial clearance of crankshaft
  74
• 3.5 Measuring radial clearance of crankshaft
  75
• 4 Auxiliary drive
  76
• 4.1 Assembly overview - ancillary drive
  76
• 4.2 Removing and installing 2nd alternator
  78
• 4.3 Removing and installing 2nd air conditioner compressor
  79
• 4.4 Removing and installing bracket for auxiliary drive
  83
• 5 Pistons and conrods
  86
• 5.1 Assembly overview - pistons and conrods
  86
• 5.2 Removing and installing pistons
  88
• 5.3 Measuring piston projection at TDC
  90
• 5.4 Checking pistons and cylinder bores
  92
• 5.5 Separating new conrod
  95
• 5.6 Checking radial clearance of conrods
  95
• 5.7 Removing and installing oil spray jets
  96
• Cylinder head, valve gear
  98
• 1 Cylinder head
  98
• 1.1 Assembly overview - cylinder head
  98
• 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
  114
• 1.6 Removing and installing injector seals
  115
• 1.7 Removing and installing camshaft housing
  117
• 1.8 Checking compression
  121
• 2 Toothed belt drive
  123
• 2.1 Assembly overview - toothed belt cover
  123
• 2.2 Assembly overview - toothed belt
  123
• 2.3 Removing and installing toothed belt guard
  125
• 2.4 Removing and installing toothed belt
  130
• 2.5 Removing toothed belt from camshaft
  145
• 3 Valve gear
  153
• 3.1 Assembly overview - valve gear
  153
• 3.2 Measuring axial play of camshaft
  155
• 3.3 Removing and installing camshaft oil seal
  156
• 3.4 Checking hydraulic compensation elements
  158
• 3.5 Removing and installing valve stem seals
  158
• 3.6 Removing and installing toothed belt pulley
  171
• 4 Inlet and exhaust valves
  173
• 4.1 Checking valve guides
  173
• 4.2 Checking valves
  174
• 4.3 Valve dimensions
  174
• Lubrication
  175
• 1 Sump, oil pump
  175
• 1.1 Assembly overview - sump/oil pump
  175
• 1.2 Engine oil:
  178
• 1.3 Removing and installing sump
  178
• 1.4 Removing and installing oil pump
  181
• 1.5 Removing and installing oil level and oil temperature sender G266
  182
• 1.6 Removing and installing toothed belt for oil pump
  183
• 2 Engine oil cooler
  184
• 3 Oil filter, oil pressure switch
  185
• 3.1 Assembly overview - oil filter housing, oil pressure switch
  185
• 3.2 Removing and installing oil pressure switch F1
  187
• 3.3 Removing and installing oil pressure switch for reduced oil pressure F378
  188
• 3.4 Checking oil pressure
  192
• 3.5 Removing and installing oil filter housing
  192
• 3.6 Removing and installing oil pressure regulating valve N428
  195
• 3.7 Measuring oil consumption
  196
• 4 Oil circuit
  197
• 4.1 Assembly overview - oil circuit
  197
• 4.2 Removing and installing oil supply line
  199
• 4.3 Removing and installing oil return line for turbocharger
  202
• Cooling
  206
• 1 Cooling system/coolant
  206
• 1.1 Assembly overview – coolant expansion tank
  206
• 1.2 Connection diagram - coolant hoses
  206
• 1.3 Checking cooling system for leaks
  208
• 1.4 Draining and adding coolant
  210
• 1.5 Removing and installing coolant expansion tank
  227
• 2 Coolant pump, regulation of cooling system
  230
• 2.1 Assembly overview - coolant pump, thermostat
  230
• 2.2 Assembly overview - electric coolant pump
  232
• 2.3 Assembly overview - coolant temperature sender
  233
• 2.4 Removing and installing pump for exhaust gas recirculation cooler V400
  233
• 2.5 Removing and installing charge air cooling pump V188
  236
• 2.6 Removing and installing auxiliary pump for heating V488
  237
• 2.7 Removing and installing coolant pump
  240
• 2.8 Removing and installing thermostat
  241
• 2.9 Checking thermostat
  242
• 2.10 Removing and installing coolant valve for cylinder head N489
  242
• 2.11 Removing and installing coolant temperature sender G62
  243
• 2.12 Removing and installing radiator outlet coolant temperature sender G83
  246
• 2.13 Removing and installing coolant temperature sender 3 G812
  247
• 2.14 Removing and installing shut-off valve
  248
• 3 Coolant pipes
  251
• 3.1 Assembly overview - coolant pipes
  251
• 3.2 Removing and installing coolant pipes
  251
• 4 Radiator, radiator fan
  255
• 4.1 Assembly overview - radiator/radiator fan
  255
• 4.2 Assembly overview - radiator cowl and radiator fan
  256
• 4.3 Removing and installing radiator
  257
• 4.4 Removing and installing radiator cowl with radiator fan
  261
• 4.5 Removing and installing radiator fan V7
  263
• 4.6 Removing and installing radiator fan 2 V177
  264
• 4.7 Removing and installing auxiliary radiator
  264
• 4.8 Removing and installing viscous fan
  267
• 4.9 Removing and installing bracket for viscous fan
  269
• Turbocharging/supercharging
  270
• 1 Turbocharger
  270
• 1.1 Assembly overview - turbocharger
  270
• 1.2 Removing and installing turbocharger
  276
• 1.3 Renewing vacuum unit for turbocharger
  284
• 1.5 Removing and installing upper connecting pipe, vehicles with bi-turbo
  299
• 1.6 Removing and installing lower connecting pipe, vehicles with bi-turbo
  300
• 1.7 Renewing turbine housing, vehicles with bi-turbo
  302
• 2 Charge air system
  307
• 2.1 Assembly overview - charge air system
  307
• 2.2 Removing and installing charge air cooler
  309
• 2.3 Removing and installing charge pressure sender 2 G447
  313
• 2.4 Checking charge air system for leaks
  314
• 2.5 Detaching and securing charge air cooler
  316
• 2.6 Removing and installing bracket for charge air cooler
  318
• 2.7 Checking charge air cooler for leaks
  319
• Mixture preparation - injection
  323
• 1 Injection system
  323
• 1.1 Filling/bleeding fuel system
  323
• 1.2 Checking fuel system for leaks
  324
• 2 Vacuum system
  325
• 2.1 Connection diagram - vacuum system
  325
• 2.2 Assembly overview - vacuum system
  328
• 2.3 Assembly overview - vacuum pipes
  329
• 2.4 Checking vacuum system
  330
• 2.5 Removing and installing solenoid valves N75/N274/N529/N316
  331
• 2.6 Removing and installing vacuum pipes
  333
• 3 Injectors/high-pressure accumulator (rail)
  335
• 3.1 Assembly overview - injectors
  335
• 3.2 Assembly overview - fuel rail
  337
• 3.3 Adapting correction values for injectors
  339
• 3.4 Testing injectors
  339
• 3.5 Testing jammed-open injectors
  340
• 3.6 Checking return flow rate of injectors with engine running
  342
• 3.7 Checking return flow rate of injectors at starter speed
  344
• 3.8 Removing and installing injectors
  346
• 3.9 Removing and installing high-pressure lines
  349
• 3.10 Removing and installing fuel rail
  354
• 4 Air filter
  357
• 4.1 Assembly overview - air filter housing
  357
• 4.2 Removing and installing air filter housing
  357
• 5 Intake manifold
  359
• 5.1 Assembly overview - intake manifold
  359
• 5.2 Removing and installing intake manifold
  361
• 5.3 Removing and installing throttle valve module GX3
  363
• 5.4 Removing and installing vacuum unit for intake manifold
  364
• 6 Senders and sensors
  366
• 6.1 Removing and installing fuel pressure regulating valve N276
  366
• 6.2 Checking fuel pressure regulating valve N276
  368
• 6.3 Removing and installing fuel pressure sender G247
  369
• 6.4 Removing and installing air mass meter G70
  371
• 6.5 Removing and installing pressure differential sender G505
  372
• 6.8 Removing and installing fuel temperature sender G81
  375
• 6.9 Removing and installing control unit for NOx sender J583/NOx sender G295
  376
• 6.11 Removing and installing control unit for NOx sender 2 J881/NOx sender 2 G687
  379
• 6.13 Removing and installing intake manifold sender GX9
  382
• 7 Engine control unit
  383
• 7.1 Removing and installing engine control unit J623
  383
• 8 High-pressure pump
  385
• 8.1 Assembly overview - high-pressure pump
  385
• 8.2 Removing and installing high-pressure pump
  386
• 8.3 Checking high-pressure pump
  391
• 9 Lambda probe
  394
• 9.1 Assembly overview - Lambda probe
  394
• 9.2 Removing and installing Lambda probe 1 before catalytic converter GX10
  395
• Exhaust system
  397
• 1 Exhaust pipes and silencers
  397
• 1.1 Assembly overview - silencers
  397
• 1.2 Removing and installing front silencer
  397
• 1.3 Aligning exhaust system free of stress
  399
• 1.4 Checking exhaust system for leaks
  399
• 1.5 Installation position of clamp
  400
• 2 Emission control
  401
• 2.1 Assembly overview - emission control
  401
• 2.2 Removing and installing catalytic converter
  403
• 2.3 Removing and installing particulate filter
  406
• 3 SCR system (selective catalytic reduction)
  410
• 3.1 Assembly overview - tank for reducing agent
  410
• 3.2 Assembly overview - delivery module for reducing agent
  411
• 3.3 Removing and installing reducing agent tank VX85
  412
• 3.4 Removing and installing delivery unit for reducing agent metering system GX19
  416
• 3.5 Removing and installing injector for reduction agent N474
  418
• 3.6 Removing and installing control unit for reducing-agent heater J891
  421
• 3.7 Draining reducing agent tank VX85
  421
• 3.8 Removing and installing filler pipe for reducing agent tank VX85
  424
• 3.9 Disconnecting reducing agent supply line
  427
• 3.10 SCR - resetting learnt values
  429
• 4 Exhaust gas temperature regulation
  430
• 4.1 Assembly overview - exhaust gas temperature regulation
  430
• 4.2 Removing and installing exhaust gas temperature sender 1 G235
  430
• 4.3 Removing and installing exhaust gas temperature sender 2 G448
  432
• 4.4 Removing and installing exhaust gas temperature sender 3 G495
  434
• 5 Exhaust gas recirculation
  436
• 5.1 Assembly overview - exhaust gas recirculation
  436
• 5.2 Removing and installing exhaust gas recirculation cooler
  438
• 5.3 Removing and installing exhaust gas recirculation pipes
  441
• 5.4 Removing and installing temperature sensor 2 for exhaust gas recirculation G690
  444
• 5.5 Checking exhaust gas recirculation cooler for leaks
  445
• 5.6 Removing and installing temperature sensor 3 for exhaust gas recirculation G949
  448
• 5.7 Removing and installing bracket for exhaust gas recirculation cooler
  450
• Glow plug system
  458
• 1 Glow plug system
  458
• 1.1 Assembly overview - glow plug system
  458
• 1.2 Removing and installing glow plug
  459
• 1.3 Checking glow plug
  463
• 1.4 Removing and installing automatic glow period control unit J179
  463
• 1.5 Removing and installing knock sensor 1 G61
  464
• 1.6 Removing and installing knock sensor 2 G66
  467
• 1.7 Removing and installing Hall sender G40
  469
• 1.8 Removing and installing engine speed sender G28
  470