4-cylinder common rail engine (2.0 l, 4V, turbocharger)

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
  3
• 2 Identification
  4
• 2.1 Engine number/engine data
  4
• 3 Repair instructions
  6
• 3.1 Rules for cleanliness
  6
• 3.2 Adapting learnt value for SCR system
  6
• 3.3 Foreign objects in engine
  6
• 3.4 Contact corrosion
  7
• 3.5 Routing and attachment of lines
  7
• 3.6 Fitting radiator and condensers
  7
• 4 Technical data
  8
• 4.1 Coolant
  8
• Removing and installing engine
  9
• 1 Removing and installing engine
  9
• 1.1 Removing engine
  9
• 1.2 Separating engine and gearbox
  19
• 1.3 Securing engine on engine and gearbox support
  20
• 1.4 Installing engine
  22
• 2 Assembly mountings
  26
• 2.1 Assembly overview - assembly mountings
  26
• 2.2 Removing and installing engine mounting
  28
• 2.3 Removing and installing gearbox mounting
  29
• 2.4 Removing and installing pendulum support
  30
• 2.5 Supporting engine in installation position
  31
• 2.6 Adjusting assembly mountings
  35
• 2.7 Checking adjustment of assembly mountings (engine and gearbox mountings)
  36
• 3 Engine cover panel
  37
• 3.1 Removing and installing engine cover
  37
• Crankshaft group
  38
• 1 Cylinder block (pulley end)
  38
• 1.1 Assembly overview - cylinder block (pulley end)
  38
• 1.2 Assembly overview - sealing flange, belt pulley end
  40
• 1.3 Removing and installing poly-V belt
  40
• 1.4 Removing and installing tensioner for poly V-belt
  42
• 1.5 Removing and installing vibration damper
  42
• 1.6 Removing and installing bracket for ancillaries
  43
• 1.7 Removing and installing engine support
  44
• 1.8 Removing and installing sealing flange on pulley end
  45
• 2 Cylinder block, gearbox end
  48
• 2.1 Assembly overview - cylinder block, gearbox end
  48
• 2.2 Removing and installing flywheel
  49
• 2.3 Removing and installing sealing flange on gearbox side
  50
• 3 Crankshaft
  59
• 3.1 Assembly overview - crankshaft
  59
• 3.2 Crankshaft dimensions
  60
• 3.3 Renewing needle bearing in crankshaft
  60
• 3.4 Measuring axial clearance of crankshaft
  62
• 4 Pistons and conrods
  64
• 4.1 Assembly overview - pistons and conrods
  64
• 4.2 Removing and installing pistons
  66
• 4.3 Measuring piston projection at TDC
  67
• 4.4 Checking pistons and cylinder bores
  69
• 4.5 Separating new conrod
  71
• 4.6 Checking radial clearance of conrods
  71
• 4.7 Removing and installing oil spray jets
  71
• Cylinder head, valve gear
  73
• 1 Cylinder head
  73
• 1.1 Assembly overview - cylinder head
  73
• 1.2 Assembly overview - cylinder head cover
  75
• 1.3 Removing and installing cylinder head
  77
• 1.4 Removing and installing cylinder head cover
  86
• 1.5 Removing and installing injector seals
  88
• 1.6 Removing and installing camshaft housing
  89
• 1.7 Checking compression
  94
• 2 Toothed belt drive
  96
• 2.1 Assembly overview - toothed belt cover
  96
• 2.2 Assembly overview - toothed belt
  97
• 2.3 Removing and installing toothed belt guard
  98
• 2.4 Removing and installing toothed belt
  101
• 2.5 Removing toothed belt from camshaft
  112
• 3 Valve gear
  117
• 3.1 Assembly overview - valve gear
  117
• 3.2 Measuring axial play of camshaft
  120
• 3.3 Removing and installing camshaft oil seal
  121
• 3.4 Removing and installing camshaft adjuster
  122
• 3.5 Removing and installing camshaft control valve 1 N205
  125
• 3.6 Removing control valve from and installing on inlet camshaft control valve 1 N205
  126
• 3.7 Checking hydraulic compensation elements
  128
• 3.8 Removing and installing valve stem seals
  129
• 4 Inlet and exhaust valves
  136
• 4.1 Checking valve guides
  136
• 4.2 Checking valves
  137
• 4.3 Valve dimensions
  137
• Lubrication
  138
• 1 Sump, oil pump
  138
• 1.1 Assembly overview - sump/oil pump
  138
• 1.2 Engine oil:
  143
• 1.3 Removing and installing sump
  143
• 1.4 Removing and installing lower part of sump
  146
• 1.5 Removing and installing upper part of sump
  150
• 1.6 Removing and installing oil pump
  154
• 1.7 Removing and installing oil level and oil temperature sender G266
  155
• 2 Engine oil cooler
  157
• 2.1 Removing and installing engine oil cooler
  157
• 3 Oil filter, oil pressure switch
  158
• 3.1 Assembly overview - oil filter housing, oil pressure switch
  158
• 3.2 Removing and installing oil pressure switch F1
  159
• 3.3 Removing and installing oil pressure switch for reduced oil pressure F378
  160
• 3.4 Checking oil pressure
  161
• 3.5 Removing and installing oil filter housing
  161
• 3.6 Removing and installing oil pressure regulating valve N428
  163
• Cooling
  165
• 1 Cooling system/coolant
  165
• 1.1 Connection diagram - coolant hoses
  165
• 1.2 Assembly overview - engine preheater
  171
• 1.3 Checking cooling system for leaks
  171
• 1.4 Draining coolant
  173
• 1.5 Filling with coolant
  175
• 1.6 Checking electric vacuum pump VAS 6096/2
  184
• 1.7 Flushing cooling system
  184
• 1.8 Flushing cooling system, quick reference guide
  205
• 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
  214
• 2.4 Removing and installing electric coolant pump
  215
• 2.5 Removing and installing coolant pump
  226
• 2.6 Removing and installing thermostat
  227
• 2.7 Checking thermostat
  227
• 2.8 Removing and installing coolant valve for cylinder head N489
  228
• 2.9 Removing and installing coolant temperature sender G62
  228
• 2.10 Removing and installing radiator outlet coolant temperature sender G83
  229
• 3 Coolant pipes
  231
• 3.1 Assembly overview - coolant pipes
  231
• 3.2 Removing and installing coolant pipes
  232
• 4 Radiator, radiator fan
  242
• 4.1 Assembly overview - radiator/radiator fan
  242
• 4.2 Removing and installing radiator
  244
• 4.3 Removing and installing water radiator for charge air cooling circuit
  245
• 4.4 Removing and installing radiator cowl with radiator fan
  248
• 4.5 Removing and installing radiator fan
  249
• Turbocharging/supercharging
  250
• 1 Exhaust turbocharger
  250
• 1.1 Assembly overview - turbocharger
  250
• 1.2 Removing and installing turbocharger
  252
• 1.3 Renewing vacuum unit for turbocharger
  255
• 1.4 Removing and installing connection for turbocharger
  260
• 2 Charge air system
  262
• 2.1 Assembly overview - charge air system
  262
• 2.2 Removing and installing charge pressure sender G31
  264
• 2.3 Checking charge air system for leaks
  264
• Mixture preparation - injection
  267
• 1 Injection system
  267
• 1.1 Schematic overview - fuel system
  267
• 1.2 Overview of fitting locations - injection system
  268
• 1.3 Filling/bleeding fuel system
  274
• 1.4 Checking fuel system for leaks
  274
• 2 Vacuum system
  275
• 2.1 Connection diagram - vacuum system
  275
• 2.2 Checking vacuum system
  276
• 3 Injectors/high-pressure accumulator (rail)
  277
• 3.1 Assembly overview - injectors
  277
• 3.2 Assembly overview - fuel rail
  279
• 3.3 Adapting correction values for injectors
  280
• 3.4 Testing injectors
  280
• 3.5 Checking return flow rate of injectors with engine running
  280
• 3.6 Checking return flow rate of injectors at starter speed
  283
• 3.7 Testing jammed-open injectors
  284
• 3.8 Removing and installing injectors
  285
• 3.9 Removing and installing high-pressure lines
  288
• 3.10 Removing and installing fuel rail
  290
• 4 Air filter
  292
• 4.1 Assembly overview - air filter housing
  292
• 4.2 Removing and installing air filter housing
  293
• 5 Intake manifold
  296
• 5.1 Assembly overview - intake manifold
  296
• 5.2 Removing and installing intake manifold
  298
• 5.3 Removing and installing throttle valve module J338
  301
• 6 Senders and sensors
  304
• 6.1 Removing and installing fuel pressure regulating valve N276
  304
• 6.2 Checking fuel pressure regulating valve N276
  310
• 6.3 Removing and installing fuel pressure sender G247
  311
• 6.4 Removing and installing air mass meter G70
  312
• 6.5 Removing and installing pressure differential sender G505
  314
• 6.6 Removing and installing exhaust gas pressure sensor 1 G450
  315
• 6.7 Removing and installing NOx sender 2 G687
  316
• 6.8 Removing and installing control unit for NOx sender GX30
  318
• 6.10 Removing and installing fuel temperature sender G81
  324
• 7 Engine control unit
  327
• 7.1 Removing and installing engine (motor) control unit J623
  327
• 8 High-pressure pump
  331
• 8.1 Assembly overview - high-pressure pump
  331
• 8.2 Removing and installing high-pressure pump
  331
• 9 Lambda probe
  335
• 9.1 Assembly overview - Lambda probe
  335
• 9.2 Removing and installing Lambda probe
  337
• Exhaust system
  341
• 1 Exhaust pipes and silencers
  341
• 1.1 Assembly overview - silencers
  341
• 1.2 Assembly overview - front exhaust pipe
  343
• 1.3 Removing and installing front exhaust pipe
  344
• 1.4 Separating exhaust pipes from silencers
  345
• 1.5 Removing and installing rear silencer
  346
• 1.6 Aligning exhaust system free of stress
  347
• 1.7 Checking exhaust system for leaks
  347
• 1.8 Installation position of clamp
  348
• 1.9 Align end exhaust pipes
  348
• 2 Exhaust gas cleaning
  350
• 2.1 Assembly overview - emission control
  350
• 2.2 Removing and installing emission control module
  352
• 2.3 Removing and installing exhaust flap control unit J883
  358
• 3 SCR system (selective catalytic reduction)
  360
• 3.1 Assembly overview - tank for reducing agent
  360
• 3.2 Assembly overview - reducing agent delivery line
  362
• 3.3 Assembly overview - delivery module for reducing agent
  363
• 3.4 Assembly overview - injector for reducing agent
  364
• 3.5 Removing and installing reducing agent tank
  365
• 3.6 Removing and installing reducing agent supply line
  367
• 3.7 Disconnecting reducing agent supply line
  370
• 3.8 Removing and installing delivery module for reducing agent
  374
• 3.9 Removing and installing injector for reduction agent N474
  376
• 3.10 Removing and installing control unit for reducing-agent heater J891
  377
• 3.11 Draining reducing agent tank
  378
• 4 Exhaust gas temperature regulation
  381
• 4.1 Assembly overview - exhaust gas temperature regulation
  381
• 4.2 Removing and installing exhaust gas temperature sender 1 G235
  384
• 4.3 Removing and installing exhaust gas temperature sender 2 G448
  385
• 4.4 Removing and installing exhaust gas temperature sender 3 G495
  388
• 4.5 Removing and installing exhaust gas temperature sender 4 G648
  389
• 5 Exhaust gas recirculation
  392
• 5.1 Assembly overview - exhaust gas recirculation
  392
• 5.2 Assembly overview - exhaust gas recirculation valve 1 GX5
  396
• 5.3 Removing and installing exhaust gas recirculation cooler
  396
• 5.4 Checking exhaust gas recirculation cooler for leaks
  399
• 5.5 Removing and installing exhaust gas recirculation valve 1 GX5
  401
• 5.6 Removing and installing exhaust gas recirculation valve 2 GX6
  402
• 5.7 Removing and installing exhaust gas recirculation temperature sensor G98
  405
• Glow plug system
  407
• 1 Glow plug system
  407
• 1.1 Assembly overview - glow plug system
  407
• 1.2 Removing and installing glow plug
  409
• 1.3 Removing and installing automatic glow period control unit J179
  411
• 1.4 Removing and installing Hall sender G40
  412
• 1.5 Removing and installing engine speed sender G28
  412