4-cylinder common rail (1.6 l and 2.0 l, 4 V, 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 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 notes
  10
• 3.1 Rules for cleanliness
  10
• 3.2 Foreign objects in engine
  10
• 3.3 Contact corrosion
  10
• 3.4 Routing and attachment of lines
  11
• 3.5 Fitting radiator and condensers
  11
• 4 Technical data
  13
• 4.1 Coolant
  14
• Removing and installing engine
  16
• 1 Removing and installing motor
  16
• 1.1 Removing motor
  16
• 1.2 Separating engine and gearbox
  28
• 1.3 Securing engine on engine and gearbox support
  32
• 1.4 Installing engine
  34
• 2 Assembly mountings
  39
• 2.1 Assembly overview – assembly mountings
  39
• 2.2 Removing and installing engine mounting
  41
• 2.3 Removing and installing gearbox mountings
  42
• 2.4 Removing and installing pendulum support
  44
• 2.5 Supporting engine in installation position
  46
• 2.6 Checking adjustment of assembly mountings (engine and gearbox mountings)
  57
• 2.7 Adjusting assembly mountings
  58
• 3 Engine cover panel
  61
• 3.1 Removing and installing engine cover
  61
• Crankshaft group
  62
• 1 Cylinder block (pulley end)
  62
• 1.1 Assembly overview - cylinder block (pulley end)
  62
• 1.2 Removing and installing poly-V belt
  64
• 1.3 Removing and installing tensioner for poly V-belt
  66
• 1.4 Removing and installing vibration damper
  67
• 1.5 Removing and installing engine support
  67
• 1.6 Removing and installing bracket for ancillaries
  69
• 1.7 Assembly overview - sealing flange, belt pulley end
  71
• 1.8 Removing and installing sealing flange on pulley end
  72
• 2 Cylinder block, gearbox end
  75
• 2.1 Assembly overview - cylinder block, gearbox end
  75
• 2.2 Removing and installing flywheel
  76
• 2.3 Removing and installing sealing flange on gearbox side
  78
• 3 Crankshaft
  99
• 3.1 Assembly overview - crankshaft
  99
• 3.2 Crankshaft dimensions
  101
• 3.3 Renewing needle bearing in crankshaft
  101
• 3.4 Measuring axial clearance of crankshaft
  104
• 4 Pistons and conrods
  106
• 4.1 Assembly overview - pistons and conrods
  106
• 4.2 Removing and installing pistons
  110
• 4.3 Measuring piston projection at TDC
  111
• 4.4 Checking pistons and cylinder bores
  114
• 4.5 Checking radial clearance of conrods
  116
• Cylinder head, valve gear
  117
• 1 Cylinder head
  117
• 1.1 Assembly overview - cylinder head
  117
• 1.2 Assembly overview - cylinder head cover
  121
• 1.3 Removing and installing cylinder head
  123
• 1.4 Removing and installing cylinder head cover
  134
• 1.5 Removing and installing injector seals
  135
• 1.6 Removing and installing camshaft housing
  136
• 1.7 Checking compression
  142
• 2 Toothed belt drive
  145
• 2.1 Assembly overview - toothed belt cover
  145
• 2.2 Assembly overview - toothed belt
  145
• 2.3 Removing and installing toothed belt guard
  147
• 2.4 Removing and installing toothed belt
  155
• 2.5 Removing toothed belt from camshaft
  168
• 3 Valve gear
  174
• 3.1 Assembly overview - valve gear
  174
• 3.2 Measuring axial play of camshaft
  177
• 3.3 Removing and installing camshaft oil seal
  178
• 3.4 Removing and installing camshaft adjuster
  180
• 3.5 Removing and installing camshaft control valve 1 N205
  184
• 3.6 Checking hydraulic compensation elements
  185
• 3.7 Removing and installing valve stem seals
  186
• 3.8 Removing and installing control valve for the camshaft adjuster
  195
• 4 Inlet and exhaust valves
  199
• 4.1 Checking valve guides
  199
• 4.2 Checking valves
  200
• 4.3 Valve dimensions
  200
• Lubrication
  201
• 1 Sump, oil pump
  201
• 1.1 Assembly overview - sump/oil pump
  201
• 1.2 Engine oil:
  207
• 1.3 Removing and installing sump
  207
• 1.4 Removing and installing lower part of sump
  211
• 1.5 Removing and installing upper part of sump
  216
• 1.6 Removing and installing oil pump
  219
• 1.7 Removing and installing oil level and oil temperature sender G266
  220
• 2 Engine oil cooler
  223
• 3 Oil filter, oil pressure switch
  224
• 3.1 Assembly overview - oil filter housing, oil pressure switch
  224
• 3.2 Removing and installing oil pressure switch F1
  226
• 3.3 Removing and installing oil pressure switch for reduced oil pressure F378
  228
• 3.4 Checking oil pressure
  230
• 3.5 Removing and installing oil filter housing
  230
• 3.6 Removing and installing oil pressure regulating valve N428
  233
• 4 Oil circuit
  235
• 4.1 Removing and installing oil supply line
  235
• 4.2 Removing and installing oil return line for turbocharger
  236
• Cooling
  238
• 1 Cooling system/coolant
  238
• 1.1 Connection diagram - coolant hoses
  238
• 1.2 Checking cooling system for leaks
  249
• 1.3 Draining coolant
  253
• 1.4 Filling with coolant
  256
• 1.5 Checking filling quality of cooling system
  268
• 1.6 Checking electric vacuum pump VAS 6096/2
  271
• 1.7 Flushing cooling system
  272
• 1.8 Flushing cooling system, quick reference guide
  294
• 2 Coolant pump, regulation of cooling system
  296
• 2.1 Assembly overview - coolant pump, thermostat
  296
• 2.2 Assembly overview - electric coolant pump
  300
• 2.3 Assembly overview - coolant temperature sender
  306
• 2.4 Removing and installing electric coolant pump
  307
• 2.5 Removing and installing coolant pump
  325
• 2.6 Removing and installing thermostat
  326
• 2.7 Checking thermostat
  330
• 2.8 Removing and installing coolant valve for cylinder head N489
  330
• 2.9 Removing and installing coolant temperature sender G62
  331
• 2.10 Removing and installing radiator outlet coolant temperature sender G83
  332
• 3 Coolant pipes
  334
• 3.1 Assembly overview - coolant pipes
  334
• 3.2 Removing and installing coolant pipes
  336
• 4 Radiator, radiator fan
  354
• 4.1 Assembly overview - radiator/radiator fan
  354
• 4.2 Assembly overview - radiator cowl and radiator fan
  360
• 4.3 Assembly overview - radiator blind
  362
• 4.4 Removing and installing radiator
  365
• 4.5 Removing and installing water radiator for charge air cooling circuit
  372
• 4.6 Removing and installing radiator cowl
  376
• 4.7 Removing and installing radiator fan
  379
• 4.8 Removing and installing radiator blind
  380
• 4.9 Removing and installing radiator blind control motor V544
  383
• Turbocharging/supercharging
  389
• 1 Turbocharger
  389
• 1.1 Assembly overview - turbocharger
  389
• 1.2 Removing and installing turbocharger
  397
• 1.3 Renewing vacuum unit for turbocharger
  416
• 1.4 Removing and installing connection for turbocharger
  425
• 2 Charge air system
  427
• 2.1 Assembly overview - charge air system
  427
• 2.2 Removing and installing charge pressure sender G31
  430
• 2.3 Checking charge air system for leaks
  430
• 2.4 Removing and installing air pipe
  433
• 2.5 Checking charge air cooler for leaks
  435
• Mixture preparation - injection
  441
• 1 Injection system
  441
• 1.1 Schematic overview - fuel system
  441
• 1.2 Overview of fitting locations - injection system
  444
• 1.3 Filling/bleeding fuel system
  458
• 1.4 Checking fuel system for leaks
  459
• 2 Vacuum system
  460
• 2.1 Connection diagram - vacuum system
  460
• 2.2 Checking vacuum system
  461
• 3 Injectors/high-pressure accumulator (rail)
  462
• 3.1 Assembly overview - injectors
  462
• 3.2 Assembly overview - fuel rail
  464
• 3.3 Adapting correction values for injectors
  465
• 3.4 Testing injectors
  466
• 3.5 Checking return flow rate of injectors with engine running
  467
• 3.6 Checking return flow rate of injectors at starter speed
  473
• 3.7 Testing jammed-open injectors
  478
• 3.8 Removing and installing injectors
  480
• 3.9 Removing and installing high-pressure lines
  486
• 3.10 Removing and installing fuel rail
  489
• 4 Air filter
  494
• 4.1 Assembly overview - air filter housing
  494
• 4.2 Removing and installing air filter housing
  496
• 5 Intake manifold
  499
• 5.1 Assembly overview - intake manifold
  499
• 5.2 Removing and installing intake manifold
  503
• 5.3 Removing and installing throttle valve module J338
  507
• 6 Senders and sensors
  511
• 6.2 Removing and installing fuel pressure regulating valve N276
  513
• 6.3 Checking fuel pressure regulating valve N276
  520
• 6.4 Removing and installing fuel pressure sender G247
  522
• 6.5 Removing and installing air mass meter G70
  523
• 6.6 Removing and installing pressure differential sender G505
  525
• 6.7 Removing and installing exhaust gas pressure sensor 1 G450
  530
• 6.8 Removing and installing NOx sender 2 G687
  531
• 6.11 Removing and installing fuel temperature sender G81
  534
• 6.12 Removing and installing control unit for NOx sender GX30
  535
• 7 Engine control unit
  546
• 7.1 Removing and installing engine control unit J623
  546
• 7.2 Removing and installing engine control unit J623 (with protective housing)
  547
• 8 High-pressure pump
  554
• 8.1 Assembly overview - high-pressure pump
  554
• 8.2 Removing and installing high-pressure pump
  555
• 9 Lambda probe
  559
• 9.1 Assembly overview - Lambda probe
  559
• 9.2 Removing and installing Lambda probe
  562
• Exhaust system
  566
• 1 Exhaust pipes and silencers
  566
• 1.1 Assembly overview - silencers
  566
• 1.2 Aligning exhaust system free of stress
  575
• 1.3 Removing and installing front exhaust pipe
  576
• 1.4 Separating exhaust pipes from silencers
  577
• 1.5 Removing and installing rear silencer
  581
• 1.6 Removing and installing silencer
  582
• 1.7 Checking exhaust system for leaks
  586
• 1.8 Assembly overview - front exhaust pipe
  586
• 1.9 Installation position of clamp
  590
• 1.10 Align end exhaust pipes
  591
• 2 Emission control
  592
• 2.1 Assembly overview - emission control
  592
• 2.2 Removing and installing catalytic converter
  597
• 2.3 Removing and installing particulate filter
  600
• 2.4 Removing and installing emission control module
  600
• 2.5 Removing and installing exhaust flap control unit J883
  610
• 3 SCR system (selective catalytic reduction)
  613
• 3.1 Assembly overview - tank for reducing agent
  613
• 3.2 Assembly overview - reducing agent supply line
  623
• 3.3 Assembly overview – filler tube for reducing agent tank
  625
• 3.4 Assembly overview - delivery module for reducing agent
  628
• 3.5 Removing and installing reducing agent tank
  629
• 3.6 Removing and installing front section of reducing agent supply line
  646
• 3.7 Removing and installing delivery module for reducing agent
  653
• 3.8 Removing and installing injector for reduction agent N474
  655
• 3.9 Removing and installing control unit for reducing-agent heater J891
  658
• 3.10 Assembly overview – injector for reducing agent N474
  668
• 3.11 Draining reducing agent tank
  670
• 3.12 Removing and installing rear section of reducing agent supply line
  673
• 3.13 Removing and installing filler pipe for reducing agent tank
  683
• 3.14 Disconnecting reducing agent supply line
  694
• 3.15 SCR - resetting learnt values
  699
• 4 Exhaust gas temperature regulation
  700
• 4.1 Assembly overview - exhaust gas temperature regulation
  700
• 4.2 Removing and installing exhaust gas temperature sender 1 G235
  704
• 4.3 Removing and installing exhaust gas temperature sender 2 G448
  707
• 4.4 Removing and installing exhaust gas temperature sender 3 G495
  713
• 4.5 Removing and installing exhaust gas temperature sender 4 G648
  717
• 5 Exhaust gas recirculation
  722
• 5.1 Assembly overview - exhaust gas recirculation
  722
• 5.2 Assembly overview - exhaust gas recirculation valve 1 GX5
  726
• 5.3 Removing and installing exhaust gas recirculation cooler
  727
• 5.4 Removing and installing exhaust gas recirculation valve 1 GX5
  734
• 5.5 Removing and installing exhaust gas recirculation valve 2 GX6
  736
• 5.6 Removing and installing exhaust gas recirculation temperature sensor G98
  737
• 5.7 Checking exhaust gas recirculation cooler for leaks
  740
• Glow plug system
  742
• 1 Glow plug system
  742
• 1.1 Assembly overview - glow plug system
  742
• 1.2 Removing and installing glow plug
  744
• 1.3 Removing and installing automatic glow period control unit J179
  747
• 1.4 Removing and installing Hall sender G40
  747
• 1.5 Removing and installing engine speed sender G28
  748