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 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
  4
• 2 Identification
  5
• 2.1 Motor number/motor data
  5
• 3 Repair instructions
  9
• 3.1 Rules for cleanliness
  9
• 3.2 Foreign objects in engine
  9
• 3.3 Contact corrosion
  9
• 3.4 Routing and attachment of lines
  10
• 3.5 Fitting radiator and condensers
  10
• 4 Technical data
  12
• 4.1 Coolant
  13
• Removing and installing engine
  15
• 1 Removing and installing engine
  15
• 1.1 Removing engine
  15
• 1.2 Separating engine and gearbox
  28
• 1.3 Securing engine on engine and gearbox support
  34
• 1.4 Installing engine
  36
• 2 Assembly mountings
  41
• 2.1 Assembly overview – assembly mountings
  41
• 2.2 Removing and installing engine mounting
  45
• 2.3 Removing and installing gearbox mounting
  46
• 2.4 Removing and installing pendulum support
  49
• 2.5 Supporting engine in installation position
  51
• 2.6 Adjusting assembly mountings
  63
• 2.7 Checking adjustment of assembly mountings
  67
• 3 Engine cover panel
  68
• 3.1 Removing and installing engine cover
  68
• Crankshaft group
  69
• 1 Cylinder block (pulley end)
  69
• 1.1 Assembly overview - cylinder block (pulley end)
  69
• 1.2 Assembly overview - sealing flange, belt pulley end
  71
• 1.3 Removing and installing poly-V belt
  73
• 1.4 Removing and installing tensioner for poly V-belt
  74
• 1.5 Removing and installing vibration damper
  75
• 1.6 Removing and installing bracket for ancillaries
  76
• 1.7 Removing and installing engine support
  78
• 1.8 Removing and installing sealing flange on pulley end
  79
• 1.9 Renewing caps in cylinder block (pulley end)
  82
• 2 Cylinder block, gearbox end
  84
• 2.1 Assembly overview - cylinder block, gearbox end
  84
• 2.2 Removing and installing flywheel
  85
• 2.3 Removing and installing sealing flange on gearbox side
  88
• 2.4 Renewing caps in cylinder block (gearbox end)
  108
• 3 Crankshaft
  110
• 3.1 Assembly overview - crankshaft
  110
• 3.2 Crankshaft dimensions
  111
• 3.3 Measuring axial clearance of crankshaft
  112
• 3.4 Renewing needle bearing in crankshaft
  113
• 4 Pistons and conrods
  116
• 4.1 Assembly overview - pistons and conrods
  116
• 4.2 Removing and installing pistons
  120
• 4.3 Measuring piston projection at TDC
  121
• 4.4 Checking pistons and cylinder bores
  124
• 4.5 Checking radial clearance of conrods
  126
• Cylinder head, valve gear
  127
• 1 Cylinder head
  127
• 1.1 Assembly overview - cylinder head
  127
• 1.2 Assembly overview - cylinder head cover
  131
• 1.3 Removing and installing cylinder head
  133
• 1.4 Removing and installing cylinder head cover
  143
• 1.5 Removing and installing injector seals
  144
• 1.6 Removing and installing camshaft housing
  146
• 1.7 Checking compression
  152
• 2 Toothed belt drive
  155
• 2.1 Assembly overview - toothed belt cover
  155
• 2.2 Assembly overview - toothed belt
  155
• 2.3 Removing and installing toothed belt guard
  157
• 2.4 Removing and installing toothed belt
  162
• 2.5 Removing toothed belt from camshaft
  176
• 3 Valve gear
  182
• 3.1 Assembly overview - valve gear
  182
• 3.2 Measuring axial play of camshaft
  186
• 3.3 Removing and installing camshaft oil seal
  186
• 3.4 Removing and installing camshaft adjuster
  189
• 3.5 Removing and installing camshaft control valve 1 N205
  192
• 3.6 Checking hydraulic compensation elements
  193
• 3.7 Removing and installing valve stem seals
  194
• 3.8 Removing and installing control valve for the camshaft adjuster
  203
• 4 Inlet and exhaust valves
  207
• 4.1 Checking valve guides
  207
• 4.2 Checking valves
  208
• 4.3 Valve dimensions
  208
• Lubrication
  209
• 1 Sump, oil pump
  209
• 1.1 Assembly overview - sump/oil pump
  209
• 1.2 Engine oil:
  215
• 1.3 Removing and installing oil sump
  216
• 1.4 Removing and installing lower part of sump
  220
• 1.5 Removing and installing upper part of sump
  224
• 1.6 Removing and installing oil pump
  228
• 1.7 Removing and installing oil level and oil temperature sender G266
  229
• 2 Engine oil cooler
  232
• 3 Oil filter, oil pressure switch
  233
• 3.1 Assembly overview - oil filter housing, oil pressure switch
  233
• 3.2 Removing and installing oil pressure switch F1
  235
• 3.3 Removing and installing oil pressure switch for reduced oil pressure F378
  237
• 3.4 Checking oil pressure
  239
• 3.5 Removing and installing oil filter housing
  239
• 3.6 Removing and installing oil pressure regulating valve N428
  242
• 4 Oil circuit
  243
• 4.1 Removing and installing oil supply line
  243
• 4.2 Removing and installing oil return line for turbocharger
  244
• Cooling
  246
• 1 Cooling system/coolant
  246
• 1.1 Connection diagram - coolant hoses
  246
• 1.2 Checking cooling system for leaks
  250
• 1.3 Draining coolant
  254
• 1.4 Filling with coolant
  257
• 1.5 Checking filling quality of cooling system
  270
• 1.6 Checking electric vacuum pump VAS 6096/2
  272
• 1.7 Flushing cooling system
  273
• 2 Coolant pump, regulation of cooling system
  297
• 2.1 Assembly overview - coolant pump, thermostat
  297
• 2.2 Assembly overview - electric coolant pump
  301
• 2.3 Assembly overview - coolant temperature sender
  307
• 2.4 Removing and installing electric coolant pump
  310
• 2.5 Removing and installing coolant pump
  328
• 2.6 Removing and installing thermostat
  328
• 2.7 Checking thermostat
  332
• 2.8 Removing and installing coolant valve for cylinder head N489
  333
• 2.9 Removing and installing coolant temperature sender G62
  333
• 2.10 Removing and installing radiator outlet coolant temperature sender G83
  335
• 3 Coolant pipes
  337
• 3.1 Assembly overview - coolant pipes
  337
• 3.2 Removing and installing coolant pipes
  339
• 4 Radiator, radiator fan
  357
• 4.1 Assembly overview - radiator/radiator fan
  357
• 4.2 Assembly overview – radiator cowl and radiator fan
  363
• 4.3 Removing and installing radiator
  364
• 4.4 Removing and installing water radiator for charge air cooling circuit
  376
• 4.5 Removing and installing radiator cowl
  382
• 4.6 Removing and installing radiator fan
  388
• Turbocharging/supercharging
  391
• 1 Turbocharger
  391
• 1.1 Assembly overview - turbocharger
  391
• 1.2 Removing and installing turbocharger
  399
• 1.3 Renewing vacuum unit for turbocharger
  415
• 1.4 Removing and installing connection for turbocharger
  424
• 2 Charge air system
  426
• 2.1 Assembly overview - charge air system
  426
• 2.2 Removing and installing charge pressure sender G31
  429
• 2.3 Checking charge air system for leaks
  429
• 2.4 Removing and installing air pipe
  432
• 2.5 Checking charge air cooler for leaks
  434
• Mixture preparation - injection
  441
• 1 Injection system
  441
• 1.1 Schematic overview - fuel system
  441
• 1.2 Overview of fitting locations - injection system
  442
• 1.3 Filling/bleeding fuel system
  452
• 1.4 Checking fuel system for leaks
  453
• 2 Vacuum system
  454
• 2.1 Connection diagram – vacuum system
  454
• 2.2 Checking vacuum system
  455
• 3 Injectors/high-pressure accumulator (rail)
  456
• 3.1 Assembly overview - injectors
  456
• 3.2 Assembly overview - fuel rail
  458
• 3.3 Adapting correction values for injectors
  459
• 3.4 Testing injectors
  460
• 3.5 Checking return flow rate of injectors with engine running
  461
• 3.6 Checking return flow rate of injectors at starter speed
  467
• 3.7 Testing jammed-open injectors
  471
• 3.8 Removing and installing injectors
  473
• 3.9 Removing and installing high-pressure lines
  478
• 3.10 Removing and installing fuel rail
  481
• 4 Air filter
  486
• 4.1 Assembly overview - air filter housing
  486
• 4.2 Removing and installing air filter housing
  488
• 4.3 Removing and installing air guide on lock carrier
  491
• 5 Intake manifold
  495
• 5.1 Assembly overview – intake manifold
  495
• 5.2 Removing and installing intake manifold
  499
• 5.3 Removing and installing throttle valve module J338
  503
• 6 Senders and sensors
  506
• 6.1 Removing and installing fuel pressure regulating valve N276
  506
• 6.2 Checking fuel pressure regulating valve N276
  513
• 6.3 Removing and installing fuel pressure sender G247
  515
• 6.4 Removing and installing air mass meter G70/intake air temperature sender G42
  516
• 6.5 Removing and installing pressure differential sender G505
  518
• 6.6 Removing and installing exhaust gas pressure sensor 1 G450
  522
• 6.7 Removing and installing NOx sender 2 G687
  523
• 6.10 Removing and installing fuel temperature sender G81
  526
• 6.11 Removing and installing control unit for NOx sender GX30
  527
• 7 Engine/motor control unit
  538
• 7.1 Removing and installing engine control unit J623
  538
• 7.2 Removing and installing engine control unit J623 (with protective housing)
  539
• 8 High-pressure pump
  546
• 8.1 Assembly overview - high-pressure pump
  546
• 8.2 Removing and installing high-pressure pump
  546
• 9 Lambda probe
  551
• 9.1 Assembly overview - Lambda probe
  551
• 9.2 Removing and installing Lambda probe
  553
• Exhaust system
  557
• 1 Exhaust pipes and silencers
  557
• 1.1 Assembly overview – silencers
  557
• 1.2 Assembly overview - front exhaust pipe
  561
• 1.3 Removing and installing front exhaust pipe
  565
• 1.4 Separating exhaust pipes from silencers
  567
• 1.5 Removing and installing silencer
  568
• 1.6 Aligning exhaust system free of stress
  574
• 1.7 Checking exhaust system for leaks
  575
• 1.8 Installation position of clamp
  575
• 1.9 Align end exhaust pipes
  577
• 1.10 Removing and installing bracket for front exhaust pipe
  577
• 2 Emission control
  579
• 2.1 Assembly overview – emission control
  579
• 2.2 Removing and installing catalytic converter
  585
• 2.3 Removing and installing particulate filter
  587
• 2.4 Removing and installing emission control module
  587
• 2.5 Removing and installing exhaust flap control unit J883
  599
• 3 SCR system (selective catalytic reduction)
  601
• 3.1 Assembly overview – reducing agent tank
  601
• 3.2 Assembly overview - reducing agent supply line
  609
• 3.3 Assembly overview - delivery module for reducing agent
  613
• 3.4 Assembly overview – filler tube for reducing agent tank
  613
• 3.5 Removing and installing reducing agent tank
  615
• 3.6 Removing and installing front section of reducing agent supply line
  628
• 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
  659
• 3.10 Assembly overview - injector for reducing agent
  666
• 3.11 Draining reducing agent tank
  668
• 3.12 Removing and installing rear section of reducing agent supply line
  671
• 3.13 Removing and installing filler pipe for reducing agent tank
  678
• 3.14 Disconnecting reducing agent supply line
  688
• 3.15 SCR - resetting learnt values
  693
• 4 Exhaust gas temperature regulation
  695
• 4.1 Assembly overview – exhaust gas temperature regulation
  695
• 4.2 Removing and installing exhaust gas temperature sender 1 G235
  697
• 4.3 Removing and installing exhaust gas temperature sender 2 G448
  702
• 4.4 Removing and installing exhaust gas temperature sender 3 G495
  705
• 4.5 Removing and installing exhaust gas temperature sender 4 G648
  707
• 5 Exhaust gas recirculation
  710
• 5.1 Assembly overview – exhaust gas recirculation
  710
• 5.2 Assembly overview - exhaust gas recirculation valve 1 GX5
  714
• 5.3 Removing and installing exhaust gas recirculation cooler
  715
• 5.4 Removing and installing exhaust gas recirculation valve 1 GX5
  723
• 5.5 Removing and installing exhaust gas recirculation valve 2 GX6
  724
• 5.6 Removing and installing exhaust gas recirculation temperature sensor G98
  725
• 5.7 Checking exhaust gas recirculation cooler for leaks
  728
• Glow plug system
  730
• 1 Glow plug system
  730
• 1.1 Assembly overview – glow plug system
  730
• 1.2 Removing and installing glow plug
  732
• 1.3 Removing and installing automatic glow period control unit J179
  735
• 1.4 Removing and installing Hall sender G40
  735
• 1.5 Removing and installing engine speed sender G28
  736