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

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety measures when 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
  9
• 4.1 Coolant
  9
• Removing and installing engine
  11
• 1 Removing and installing engine
  11
• 1.1 Removing engine
  11
• 1.2 Separating engine and gearbox
  21
• 1.3 Securing engine on engine and gearbox support
  22
• 1.4 Installing engine
  24
• 2 Assembly mountings
  28
• 2.1 Assembly overview - assembly mountings
  28
• 2.2 Removing and installing engine mounting
  30
• 2.3 Removing and installing gearbox mounting
  31
• 2.4 Removing and installing pendulum support
  32
• 2.5 Supporting engine in installation position
  33
• 2.6 Adjusting assembly mountings
  38
• 2.7 Checking adjustment of assembly mountings (engine and gearbox mountings)
  39
• 3 Engine cover panel
  40
• 3.1 Removing and installing engine cover
  40
• Crankshaft group
  41
• 1 Cylinder block (pulley end)
  41
• 1.1 Assembly overview - cylinder block (pulley end)
  41
• 1.2 Assembly overview - sealing flange, belt pulley end
  43
• 1.3 Removing and installing poly-V belt
  43
• 1.4 Removing and installing tensioner for poly V-belt
  45
• 1.5 Removing and installing vibration damper
  45
• 1.6 Removing and installing bracket for ancillaries
  46
• 1.7 Removing and installing engine support
  47
• 1.8 Removing and installing sealing flange on pulley end
  48
• 2 Cylinder block, gearbox end
  51
• 2.1 Assembly overview - cylinder block, gearbox end
  51
• 2.2 Removing and installing flywheel
  52
• 2.3 Removing and installing sealing flange on gearbox side
  53
• 3 Crankshaft
  62
• 3.1 Assembly overview - crankshaft
  62
• 3.2 Crankshaft dimensions
  63
• 3.3 Renewing needle bearing in crankshaft
  63
• 3.4 Measuring axial clearance of crankshaft
  65
• 4 Pistons and conrods
  67
• 4.1 Assembly overview - pistons and conrods
  67
• 4.2 Removing and installing pistons
  69
• 4.3 Measuring piston projection at TDC
  70
• 4.4 Checking pistons and cylinder bores
  72
• 4.5 Separating new conrod
  74
• 4.6 Checking radial clearance of conrods
  74
• 4.7 Removing and installing oil spray jets
  74
• Cylinder head, valve gear
  76
• 1 Cylinder head
  76
• 1.1 Assembly overview - cylinder head
  76
• 1.2 Assembly overview - cylinder head cover
  78
• 1.3 Removing and installing cylinder head
  80
• 1.4 Removing and installing cylinder head cover
  90
• 1.5 Removing and installing injector seals
  92
• 1.6 Removing and installing camshaft housing
  94
• 1.7 Checking compression
  98
• 2 Toothed belt drive
  100
• 2.1 Assembly overview - toothed belt cover
  100
• 2.2 Assembly overview - toothed belt
  101
• 2.3 Removing and installing toothed belt guard
  102
• 2.4 Removing and installing toothed belt
  105
• 2.5 Removing toothed belt from camshaft
  116
• 3 Valve gear
  121
• 3.1 Assembly overview - valve gear
  121
• 3.2 Measuring axial play of camshaft
  124
• 3.3 Removing and installing camshaft oil seal
  125
• 3.4 Removing and installing camshaft adjuster
  126
• 3.5 Removing and installing camshaft control valve 1 N205
  129
• 3.6 Removing control valve from and installing on inlet camshaft control valve 1 N205
  130
• 3.7 Checking hydraulic compensation elements
  132
• 3.8 Removing and installing valve stem seals
  133
• 4 Inlet and exhaust valves
  140
• 4.1 Checking valve guides
  140
• 4.2 Checking valves
  141
• 4.3 Valve dimensions
  141
• Lubrication
  142
• 1 Sump, oil pump
  142
• 1.1 Assembly overview - sump/oil pump
  142
• 1.2 Engine oil:
  147
• 1.3 Removing and installing sump
  147
• 1.4 Removing and installing lower part of sump
  150
• 1.5 Removing and installing upper part of sump
  154
• 1.6 Removing and installing oil pump
  158
• 1.7 Removing and installing oil level and oil temperature sender G266
  159
• 2 Engine oil cooler
  161
• 2.1 Removing and installing engine oil cooler
  161
• 3 Oil filter, oil pressure switch
  162
• 3.1 Assembly overview - oil filter housing, oil pressure switch
  162
• 3.2 Removing and installing oil pressure switch F1
  163
• 3.3 Removing and installing oil pressure switch for reduced oil pressure F378
  164
• 3.4 Checking oil pressure
  165
• 3.5 Removing and installing oil filter housing
  165
• 3.6 Removing and installing oil pressure regulating valve N428
  167
• Cooling
  169
• 1 Cooling system/coolant
  169
• 1.1 Connection diagram - coolant hoses
  169
• 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
  174
• 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
  227
• 2.6 Removing and installing thermostat
  228
• 2.7 Checking thermostat
  228
• 2.8 Removing and installing coolant valve for cylinder head N489
  229
• 2.9 Removing and installing coolant temperature sender G62
  229
• 2.10 Removing and installing radiator outlet coolant temperature sender G83
  230
• 3 Coolant pipes
  232
• 3.1 Assembly overview - coolant pipes
  232
• 3.2 Removing and installing coolant pipes
  233
• 4 Radiator, radiator fan
  244
• 4.1 Assembly overview - radiator/radiator fan
  244
• 4.2 Removing and installing radiator
  246
• 4.3 Removing and installing water radiator for charge air cooling circuit
  247
• 4.4 Removing and installing radiator cowl with radiator fan
  250
• 4.5 Removing and installing radiator fan
  251
• Turbocharging/supercharging
  252
• 1 Turbocharger
  252
• 1.1 Assembly overview - turbocharger
  252
• 1.2 Removing and installing turbocharger
  254
• 1.3 Renewing vacuum unit for turbocharger
  258
• 1.4 Removing and installing connection for turbocharger
  263
• 2 Charge air system
  265
• 2.1 Assembly overview - charge air system
  265
• 2.2 Removing and installing charge pressure sender G31
  267
• 2.3 Checking charge air system for leaks
  267
• Mixture preparation - injection
  270
• 1 Injection system
  270
• 1.1 Schematic overview - fuel system
  270
• 1.2 Overview of fitting locations - injection system
  271
• 1.3 Filling/bleeding fuel system
  277
• 1.4 Checking fuel system for leaks
  277
• 2 Vacuum system
  278
• 2.1 Connection diagram - vacuum system
  278
• 2.2 Checking vacuum system
  278
• 3 Injectors/high-pressure accumulator (rail)
  280
• 3.1 Assembly overview - injectors
  280
• 3.2 Assembly overview - fuel rail
  282
• 3.3 Adapting correction values for injectors
  283
• 3.4 Testing injectors
  283
• 3.5 Checking return flow rate of injectors with engine running
  283
• 3.6 Checking return flow rate of injectors at starter speed
  286
• 3.7 Testing jammed-open injectors
  287
• 3.8 Removing and installing injectors
  288
• 3.9 Removing and installing high-pressure lines
  291
• 3.10 Removing and installing fuel rail
  293
• 4 Air filter
  295
• 4.1 Assembly overview - air filter housing
  295
• 4.2 Removing and installing air filter housing
  296
• 5 Intake manifold
  299
• 5.1 Assembly overview - intake manifold
  299
• 5.2 Removing and installing intake manifold
  301
• 5.3 Removing and installing throttle valve module J338
  304
• 6 Senders and sensors
  307
• 6.1 Removing and installing fuel pressure regulating valve N276
  307
• 6.2 Checking fuel pressure regulating valve N276
  313
• 6.3 Removing and installing fuel pressure sender G247
  314
• 6.4 Removing and installing air mass meter G70
  315
• 6.5 Removing and installing pressure differential sender G505
  317
• 6.6 Removing and installing exhaust gas pressure sensor 1 G450
  318
• 6.7 Removing and installing NOx sender 2 G687
  319
• 6.8 Removing and installing control unit for NOx sender GX30
  321
• 6.10 Removing and installing fuel temperature sender G81
  327
• 7 Engine control unit
  330
• 7.1 Removing and installing engine (motor) control unit J623
  330
• 8 High-pressure pump
  334
• 8.1 Assembly overview - high-pressure pump
  334
• 8.2 Removing and installing high-pressure pump
  334
• 9 Lambda probe
  338
• 9.1 Assembly overview - Lambda probe
  338
• 9.2 Removing and installing Lambda probe
  340
• Exhaust system
  343
• 1 Exhaust pipes and silencers
  343
• 1.1 Assembly overview - silencers
  343
• 1.2 Assembly overview - front exhaust pipe
  345
• 1.3 Removing and installing front exhaust pipe
  346
• 1.4 Separating exhaust pipes from silencers
  347
• 1.5 Removing and installing rear silencer
  348
• 1.6 Aligning exhaust system free of stress
  349
• 1.7 Checking exhaust system for leaks
  349
• 1.8 Installation position of clamp
  350
• 1.9 Align end exhaust pipes
  350
• 2 Emission control
  352
• 2.1 Assembly overview - emission control
  352
• 2.2 Removing and installing emission control module
  354
• 2.3 Removing and installing exhaust flap control unit J883
  360
• 3 SCR system (selective catalytic reduction)
  362
• 3.1 Assembly overview - tank for reducing agent
  362
• 3.2 Assembly overview - reducing agent delivery line
  364
• 3.3 Assembly overview - delivery module for reducing agent
  365
• 3.4 Assembly overview - injector for reducing agent
  366
• 3.5 Removing and installing reducing agent tank
  367
• 3.6 Removing and installing reducing agent supply line
  369
• 3.7 Removing and installing reducing agent supply line
  371
• 3.8 Disconnecting reducing agent supply line
  375
• 3.9 Removing and installing delivery module for reducing agent
  379
• 3.10 Removing and installing injector for reduction agent N474
  381
• 3.11 Removing and installing control unit for reducing-agent heater J891
  382
• 3.12 Draining reducing agent tank
  383
• 4 Exhaust gas temperature regulation
  386
• 4.1 Assembly overview - exhaust gas temperature regulation
  386
• 4.2 Removing and installing exhaust gas temperature sender 1 G235
  389
• 4.3 Removing and installing exhaust gas temperature sender 2 G448
  390
• 4.4 Removing and installing exhaust gas temperature sender 3 G495
  393
• 4.5 Removing and installing exhaust gas temperature sender 4 G648
  394
• 5 Exhaust gas recirculation
  397
• 5.1 Assembly overview - exhaust gas recirculation
  397
• 5.2 Assembly overview - exhaust gas recirculation valve 1 GX5
  401
• 5.3 Removing and installing exhaust gas recirculation cooler
  401
• 5.4 Checking exhaust gas recirculation cooler for leaks
  404
• 5.5 Removing and installing exhaust gas recirculation valve 1 GX5
  407
• 5.6 Removing and installing exhaust gas recirculation valve 2 GX6
  408
• 5.7 Removing and installing exhaust gas recirculation temperature sensor G98
  411
• Glow plug system
  413
• 1 Glow plug system
  413
• 1.1 Assembly overview - glow plug system
  413
• 1.2 Removing and installing glow plug
  415
• 1.3 Removing and installing automatic glow period control unit J179
  417
• 1.4 Removing and installing Hall sender G40
  418
• 1.5 Removing and installing engine speed sender G28
  418