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 start/stop system
  1
• 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 ignition system
  3
• 1.7 Safety precautions when working on exhaust system
  3
• 2 Identification
  5
• 2.1 Engine number/engine data
  5
• 3 Repair notes
  7
• 3.1 Rules for cleanliness
  7
• 3.2 General information
  7
• 3.3 General repair instructions
  8
• 3.4 Foreign objects in engine
  8
• 3.5 Contact corrosion
  8
• 3.6 Routing and attachment of lines
  9
• 3.7 Fitting radiators and condensers
  9
• 3.8 Checking vacuum system
  9
• Removing and installing engine
  10
• 1 Removing and installing engine
  10
• 1.1 Removing engine
  10
• 1.2 Separating engine and gearbox
  18
• 1.3 Securing engine on engine and gearbox support
  22
• 1.4 Installing engine
  23
• 2 Assembly mountings
  27
• 2.1 Assembly overview – assembly mountings
  27
• 2.2 Removing and installing engine mounting
  30
• 2.3 Removing and installing gearbox mounting
  32
• 2.4 Removing and installing pendulum support
  33
• 2.5 Supporting engine in installation position
  34
• 2.6 Adjusting assembly mountings
  37
• 2.7 Checking adjustment of assembly mountings
  40
• 3 Engine cover panel
  42
• 3.1 Removing and installing engine cover
  42
• Crankshaft group
  43
• 1 Cylinder block (pulley end)
  43
• 1.1 Assembly overview - cylinder block (pulley end)
  43
• 1.2 Assembly overview - sealing flange, belt pulley end
  45
• 1.3 Removing and installing poly-V belt
  47
• 1.4 Removing and installing tensioner for poly V-belt
  49
• 1.5 Removing and installing vibration damper
  49
• 1.6 Removing and installing bracket for ancillaries
  50
• 1.7 Removing and installing engine support
  52
• 1.8 Removing and installing sealing flange on pulley end
  53
• 2 Cylinder block, gearbox end
  56
• 2.1 Assembly overview - cylinder block, gearbox end
  56
• 2.2 Removing and installing flywheel
  57
• 2.3 Removing and installing sealing flange on gearbox side
  59
• 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 Pistons and conrods
  76
• 4.1 Assembly overview - pistons and conrods
  76
• 4.2 Removing and installing pistons
  79
• 4.3 Measuring piston projection at TDC
  80
• 4.4 Checking pistons and cylinder bores
  82
• 4.5 Separating new conrod
  85
• 4.6 Checking radial clearance of conrods
  85
• 4.7 Removing and installing oil spray jets
  86
• Cylinder head, valve gear
  88
• 1 Cylinder head
  88
• 1.1 Assembly overview - cylinder head
  88
• 1.2 Assembly overview - camshaft housing
  91
• 1.3 Assembly overview - cylinder head cover
  91
• 1.4 Removing and installing cylinder head
  93
• 1.5 Removing and installing cylinder head cover
  100
• 1.6 Removing and installing injector seals
  102
• 1.7 Removing and installing camshaft housing
  104
• 1.8 Checking compression
  110
• 2 Toothed belt drive
  112
• 2.1 Assembly overview - toothed belt cover
  112
• 2.2 Assembly overview - toothed belt
  112
• 2.3 Removing and installing toothed belt guard
  114
• 2.4 Removing and installing toothed belt
  119
• 2.5 Removing toothed belt from camshaft
  132
• 3 Valve gear
  137
• 3.1 Assembly overview - valve gear
  137
• 3.2 Measuring axial play of camshaft
  141
• 3.3 Removing and installing camshaft oil seal
  142
• 3.4 Removing and installing camshaft adjuster
  144
• 3.5 Checking hydraulic compensation elements
  147
• 3.6 Removing and installing valve stem seals
  148
• 4 Inlet and exhaust valves
  158
• 4.1 Checking valve guides
  158
• 4.2 Checking valves
  159
• 4.3 Valve dimensions
  159
• Lubrication
  160
• 1 Sump, oil pump
  160
• 1.1 Assembly overview - sump/oil pump
  160
• 1.2 Engine oil
  163
• 1.3 Removing and installing oil sump
  163
• 1.4 Removing and installing oil pump
  165
• 1.5 Removing and installing oil level and oil temperature sender G266
  167
• 2 Engine oil cooler
  169
• 3 Oil filter, oil pressure switch
  170
• 3.1 Assembly overview - oil filter housing, oil pressure switch
  170
• 3.2 Removing and installing oil pressure switch F1
  172
• 3.3 Removing and installing oil pressure switch for reduced oil pressure F378
  174
• 3.4 Checking oil pressure
  176
• 3.5 Removing and installing oil filter housing
  176
• 3.6 Removing and installing oil pressure regulating valve N428
  179
• 4 Oil circuit
  181
• 4.1 Removing and installing oil supply line
  181
• 4.2 Removing and installing oil return line for turbocharger
  184
• Cooling
  187
• 1 Cooling system/coolant
  187
• 1.1 Connection diagram - coolant hoses
  187
• 1.2 Draining and adding coolant
  191
• 1.3 Checking cooling system for leaks
  197
• 2 Coolant pump, regulation of cooling system
  200
• 2.1 Assembly overview - coolant pump, thermostat
  200
• 2.2 Assembly overview - coolant temperature sender
  204
• 2.3 Assembly overview - electric coolant pump
  204
• 2.4 Removing and installing coolant pump
  205
• 2.5 Removing and installing charge air cooling pump V188
  206
• 2.6 Removing and installing auxiliary pump for heating V488
  208
• 2.7 Removing and installing thermostat
  210
• 2.8 Checking thermostat
  214
• 2.9 Removing and installing coolant temperature sender G62
  214
• 2.10 Removing and installing coolant valve for cylinder head N489
  216
• 3 Coolant pipes
  217
• 3.1 Assembly overview - coolant pipes
  217
• 3.2 Removing and installing coolant pipes
  219
• 4 Radiator, radiator fan
  233
• 4.1 Assembly overview - radiator/radiator fan
  233
• 4.2 Assembly overview – radiator cowl and radiator fan
  235
• 4.3 Removing and installing radiator
  235
• 4.4 Removing and installing radiator cowl with radiator fan
  237
• 4.5 Removing and installing radiator fan VX57
  238
• 4.6 Removing and installing radiator fan 2 V177
  239
• 4.7 Removing and installing auxiliary radiator
  240
• Turbocharging/supercharging
  244
• 1 Turbocharger
  244
• 1.1 Assembly overview - turbocharger
  244
• 1.2 Removing and installing turbocharger
  250
• 1.3 Renewing vacuum unit for turbocharger
  256
• 1.4 Removing and installing connection for turbocharger
  259
• 1.5 Removing and installing pulsation damper
  261
• 2 Charge air system
  263
• 2.1 Assembly overview - charge air system
  263
• 2.2 Removing and installing charge air cooler
  263
• 2.3 Removing and installing charge pressure sender G31
  263
• 2.4 Checking charge air system for leaks
  264
• 2.5 Removing and installing charge air pipe
  266
• Mixture preparation - injection
  267
• 1 Injection system
  267
• 1.1 Schematic overview - fuel system
  267
• 1.2 Filling/bleeding fuel system
  268
• 1.3 Checking fuel system for leaks
  269
• 2 Vacuum system
  270
• 2.1 Connection diagram – vacuum system
  270
• 3 Injectors/high-pressure accumulator (rail)
  271
• 3.1 Assembly overview - injectors
  271
• 3.2 Assembly overview - fuel rail
  273
• 3.3 Adapting correction values for injectors
  274
• 3.4 Checking return flow rate of injectors with engine running
  276
• 3.5 Checking return flow rate of injectors at starter speed
  279
• 3.6 Testing jammed-open injectors
  280
• 3.7 Removing and installing injectors
  282
• 3.8 Removing and installing high-pressure lines
  286
• 3.9 Removing and installing fuel rail
  292
• 4 Air filter
  294
• 4.1 Assembly overview - air filter housing
  294
• 4.2 Removing and installing air filter housing
  296
• 4.3 Removing and installing air guide on lock carrier
  298
• 5 Intake manifold
  300
• 5.1 Assembly overview – intake manifold
  300
• 5.2 Removing and installing intake manifold
  303
• 5.3 Removing and installing throttle valve module GX3
  307
• 6 Senders and sensors
  310
• 6.1 Removing and installing fuel temperature sender G81
  310
• 6.2 Removing and installing air mass meter G70
  311
• 6.3 Removing and installing fuel pressure regulating valve N276
  312
• 6.4 Checking fuel pressure regulating valve N276
  314
• 6.5 Removing and installing fuel pressure sender G247
  316
• 6.6 Removing and installing pressure differential sender G505
  317
• 6.7 Removing and installing exhaust gas pressure sensor 1 G450
  319
• 6.8 Removing and installing control unit for NOx sender J583/NOx sender G295
  320
• 6.9 Removing and installing control unit for NOx sender 2 J881/NOx sender 2 G687
  322
• 7 Engine control unit
  325
• 7.1 Removing and installing engine control unit J623
  325
• 8 High-pressure pump
  329
• 8.1 Assembly overview - high-pressure pump
  329
• 8.2 Removing and installing high-pressure pump
  329
• 8.3 Checking high-pressure pump
  333
• 9 Lambda probe
  337
• 9.1 Assembly overview - Lambda probe
  337
• 9.2 Removing and installing Lambda probe 1 before catalytic converter GX10
  338
• Exhaust system
  341
• 1 Exhaust pipes and silencers
  341
• 1.1 Assembly overview – silencers
  341
• 1.2 Assembly overview - front exhaust pipe
  342
• 1.3 Removing and installing front exhaust pipe
  345
• 1.4 Separating exhaust pipes and silencers
  352
• 1.5 Removing and installing rear silencer
  353
• 1.6 Aligning exhaust system free of stress
  354
• 1.7 Checking exhaust system for leaks
  355
• 1.8 Installation position of clamp
  355
• 2 Emission control
  357
• 2.1 Assembly overview – emission control
  357
• 2.2 Removing and installing catalytic converter
  365
• 2.3 Removing and installing particulate filter
  365
• 2.4 Removing and installing emission control module
  371
• 2.5 Removing and installing exhaust flap control unit J883
  380
• 3 SCR system (selective catalytic reduction)
  382
• 3.1 Assembly overview – reducing agent tank
  382
• 3.2 Assembly overview - delivery module for reducing agent
  383
• 3.3 Assembly overview - injector for reducing agent
  383
• 3.4 Draining reducing agent tank VX85
  384
• 3.5 Removing and installing reducing agent tank VX85
  387
• 3.6 Removing and installing front section of reducing agent supply line
  390
• 3.7 Removing and installing delivery unit for reducing agent metering system GX19
  393
• 3.8 Removing and installing injector for reduction agent N474
  396
• 3.9 Removing and installing control unit for reducing-agent heater J891
  399
• 4 Exhaust gas temperature regulation
  400
• 4.1 Assembly overview – exhaust gas temperature regulation
  400
• 4.2 Removing and installing exhaust gas temperature sender 1 G235
  402
• 4.3 Removing and installing exhaust gas temperature sender 2 G448
  406
• 4.4 Removing and installing exhaust gas temperature sender 3 G495
  407
• 4.5 Removing and installing exhaust gas temperature sender 4 G648
  409
• 5 Exhaust gas recirculation
  412
• 5.1 Assembly overview – exhaust gas recirculation
  412
• 5.2 Assembly overview - exhaust gas recirculation valve
  416
• 5.3 Removing and installing exhaust gas recirculation cooler
  417
• 5.4 Checking exhaust gas recirculation cooler for leaks
  426
• 5.5 Removing and installing exhaust gas recirculation valve 1 GX5
  426
• 5.6 Removing and installing exhaust gas recirculation valve 2 GX6
  427
• 5.7 Removing and installing bracket for exhaust gas recirculation cooler
  429
• 5.8 Removing and installing exhaust gas recirculation pipes
  431
• 5.9 Removing and installing exhaust gas recirculation temperature sensor G98
  435
• Glow plug system
  438
• 1 Glow plug system
  438
• 1.1 Assembly overview – glow plug system
  438
• 1.2 Removing and installing glow plug
  439
• 1.3 Removing and installing automatic glow period control unit J179
  442
• 1.4 Removing and installing Hall sender G40
  443
• 1.5 Removing and installing engine speed sender G28
  444