4-cylinder common rail engine (2.0 l, 4V, 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 SCR system
  2
• 1.6 Safety precautions when working on exhaust system
  4
• 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 Adapting after component replacement
  9
• 3.5 Foreign objects in engine
  9
• 3.6 Contact corrosion
  9
• 3.7 Routing and attachment of lines
  10
• 3.8 Fitting radiator and condensers
  10
• 3.9 Checking vacuum system
  10
• 3.10 Nuts and bolts
  11
• 3.11 Identification labels
  11
• 3.12 Using impact drivers
  11
• 3.13 Checking fuel system for leaks
  12
• 4 Technical data
  14
• 4.1 Coolant
  15
• Removing and installing engine
  17
• 1 Removing and installing engine
  17
• 1.1 Removing engine
  17
• 1.2 Separating engine and gearbox
  31
• 1.3 Securing engine on engine and gearbox support
  36
• 1.4 Installing engine
  38
• 2 Assembly mountings
  43
• 2.1 Assembly overview – assembly mountings
  43
• 2.2 Removing and installing engine mounting
  45
• 2.3 Removing and installing gearbox mounting
  47
• 2.4 Removing and installing pendulum support
  50
• 2.5 Supporting engine in installation position
  50
• 2.6 Adjusting assembly mountings
  56
• 2.7 Checking adjustment of assembly mountings
  59
• 3 Engine cover panel
  60
• 3.1 Removing and installing engine cover
  60
• Crankshaft group
  61
• 1 Cylinder block (pulley end)
  61
• 1.1 Assembly overview - cylinder block (pulley end)
  61
• 1.2 Assembly overview - sealing flange, belt pulley end
  64
• 1.3 Removing and installing poly-V belt
  65
• 1.4 Removing and installing tensioner for poly V-belt
  66
• 1.5 Removing and installing vibration damper
  67
• 1.6 Removing and installing bracket for ancillaries
  68
• 1.7 Removing and installing engine support
  70
• 1.8 Removing and installing sealing flange on pulley end
  71
• 1.9 Renewing caps in cylinder block (pulley end)
  75
• 2 Cylinder block, gearbox end
  77
• 2.1 Assembly overview - cylinder block, gearbox end
  77
• 2.2 Removing and installing flywheel
  78
• 2.3 Removing and installing sealing flange on gearbox side
  80
• 3 Crankshaft
  102
• 3.1 Assembly overview - crankshaft
  102
• 3.2 Crankshaft dimensions
  103
• 3.3 Measuring axial clearance of crankshaft
  104
• 3.4 Renewing needle bearing in crankshaft
  105
• 4 Pistons and conrods
  108
• 4.1 Assembly overview - pistons and conrods
  108
• 4.2 Removing and installing pistons
  111
• 4.3 Measuring piston projection at TDC
  113
• 4.4 Separating new conrod
  115
• 4.5 Checking pistons and cylinder bores
  116
• 4.6 Checking radial clearance of conrods
  118
• Cylinder head, valve gear
  119
• 1 Cylinder head
  119
• 1.1 Assembly overview - cylinder head
  119
• 1.2 Assembly overview - cylinder head cover
  123
• 1.3 Removing and installing cylinder head
  125
• 1.4 Removing and installing cylinder head cover
  136
• 1.5 Removing and installing injector seals
  137
• 1.6 Removing and installing camshaft housing
  138
• 1.7 Checking compression
  145
• 2 Toothed belt drive
  148
• 2.1 Assembly overview - toothed belt cover
  148
• 2.2 Assembly overview - toothed belt
  148
• 2.3 Removing and installing toothed belt guard
  150
• 2.4 Removing and installing toothed belt
  155
• 2.5 Removing toothed belt from camshaft
  169
• 3 Valve gear
  175
• 3.1 Assembly overview - valve gear
  175
• 3.2 Measuring axial play of camshaft
  179
• 3.3 Removing and installing camshaft oil seal
  179
• 3.4 Removing and installing camshaft adjuster
  182
• 3.5 Removing and installing camshaft control valve 1 N205
  185
• 3.6 Checking hydraulic compensation elements
  186
• 3.7 Removing and installing valve stem oil seals
  187
• 3.8 Removing and installing control valve for the camshaft adjuster
  197
• 4 Inlet and exhaust valves
  201
• 4.1 Checking valve guides
  201
• 4.2 Checking valves
  202
• 4.3 Valve dimensions
  202
• Lubrication
  203
• 1 Sump, oil pump
  203
• 1.1 Assembly overview - sump/oil pump
  203
• 1.2 Engine oil:
  209
• 1.3 Removing and installing sump
  209
• 1.4 Removing and installing lower part of sump
  213
• 1.5 Removing and installing upper part of sump
  217
• 1.6 Removing and installing oil pump
  222
• 1.7 Removing and installing oil level and oil temperature sender G266
  223
• 2 Engine oil cooler
  226
• 3 Oil filter, oil pressure switch
  227
• 3.1 Assembly overview - oil filter housing, oil pressure switch
  227
• 3.2 Removing and installing oil pressure switch F1
  229
• 3.3 Removing and installing oil pressure switch for reduced oil pressure F378
  231
• 3.4 Checking oil pressure
  233
• 3.5 Removing and installing oil filter housing
  234
• 3.6 Removing and installing oil pressure regulating valve N428
  237
• Cooling
  238
• 1 Cooling system/coolant
  238
• 1.1 Connection diagram - coolant hoses
  238
• 1.2 Assembly overview – coolant expansion tank
  242
• 1.3 Checking cooling system for leaks
  243
• 1.4 Draining coolant
  247
• 1.5 Filling with coolant
  250
• 1.6 Checking filling quality
  262
• 1.7 Checking electric vacuum pump VAS 6096/2
  265
• 1.8 Flushing cooling system
  266
• 1.9 Flushing cooling system, quick reference guide
  289
• 1.10 Removing and installing coolant expansion tank
  290
• 2 Coolant pump, regulation of cooling system
  293
• 2.1 Assembly overview - coolant pump, thermostat
  293
• 2.2 Assembly overview - electric coolant pump
  297
• 2.3 Assembly overview - coolant temperature sender
  303
• 2.4 Removing and installing electric coolant pump
  306
• 2.5 Removing and installing coolant pump
  324
• 2.6 Removing and installing thermostat
  325
• 2.7 Checking thermostat
  329
• 2.8 Removing and installing coolant valve for cylinder head N489
  329
• 2.9 Removing and installing coolant temperature sender G62
  330
• 2.10 Removing and installing radiator outlet coolant temperature sender G83
  331
• 3 Coolant pipes
  334
• 3.1 Assembly overview - coolant pipes
  334
• 3.2 Removing and installing coolant pipes
  336
• 4 Radiator, radiator fan
  355
• 4.1 Assembly overview - radiator/radiator fan
  355
• 4.2 Assembly overview – radiator cowl and radiator fan
  358
• 4.3 Removing and installing radiator
  360
• 4.4 Removing and installing water radiator for charge air cooling circuit
  362
• 4.5 Removing and installing radiator cowl
  367
• 4.6 Removing and installing radiator fan
  370
• Turbocharging/supercharging
  372
• 1 Turbocharger
  372
• 1.1 Assembly overview - turbocharger
  372
• 1.2 Removing and installing turbocharger
  381
• 1.3 Renewing vacuum unit for turbocharger
  399
• 1.4 Removing and installing connection for turbocharger
  408
• 2 Charge air system
  410
• 2.1 Assembly overview - charge air system
  410
• 2.2 Assembly overview - charge-air hose connections
  412
• 2.3 Removing and installing charge pressure sender G31
  413
• 2.4 Checking charge air system for leaks
  414
• 2.5 Removing and installing air intake pipe
  417
• 2.6 Checking charge air cooler for leaks
  418
• Mixture preparation - injection
  424
• 1 Injection system
  424
• 1.1 Schematic overview - fuel system
  424
• 1.2 Overview of fitting locations - injection system
  425
• 1.3 Filling/bleeding fuel system
  433
• 1.4 Checking fuel system for leaks
  434
• 2 Vacuum system
  435
• 2.1 Connection diagram – vacuum system
  435
• 2.2 Checking vacuum system
  436
• 3 Injectors/high-pressure accumulator (rail)
  437
• 3.1 Assembly overview - injectors
  437
• 3.2 Assembly overview - fuel rail
  439
• 3.3 Adapting correction values for injectors
  440
• 3.4 Testing injectors
  441
• 3.5 Checking return flow rate of injectors with engine running
  442
• 3.6 Checking return flow rate of injectors at starter speed
  445
• 3.7 Checking open injectors
  447
• 3.8 Removing and installing injectors
  450
• 3.9 Removing and installing high-pressure lines
  453
• 3.10 Removing and installing fuel rail
  457
• 4 Air filter
  461
• 4.1 Assembly overview - air filter housing
  461
• 4.2 Removing and installing air filter housing
  463
• 4.3 Removing and installing air guide on lock carrier
  465
• 5 Intake manifold
  466
• 5.1 Assembly overview – intake manifold
  466
• 5.2 Removing and installing intake manifold
  469
• 5.3 Removing and installing throttle valve module J338
  474
• 6 Senders and sensors
  477
• 6.1 Removing and installing fuel pressure regulating valve N276
  477
• 6.2 Checking fuel pressure regulating valve N276
  484
• 6.3 Removing and installing fuel pressure sender G247
  486
• 6.4 Removing and installing air mass meter G70/intake air temperature sender G42
  487
• 6.5 Removing and installing pressure differential sender G505
  489
• 6.6 Removing and installing exhaust gas pressure sensor 1 G450
  492
• 6.9 Removing and installing fuel temperature sender G81
  494
• 6.10 Removing and installing control unit for NOx sender GX30
  496
• 7 Engine control unit
  501
• 7.1 Assembly overview – engine/motor control unit
  501
• 7.2 Removing and installing engine control unit J623
  501
• 7.3 Removing and installing engine (motor) control unit J623 with protective housing
  503
• 8 High-pressure pump
  509
• 8.1 Assembly overview - high-pressure pump
  509
• 8.2 Removing and installing high-pressure pump
  510
• 9 Lambda probe
  514
• 9.1 Assembly overview - Lambda probe
  514
• 9.2 Removing and installing Lambda probe
  516
• Exhaust system
  520
• 1 Exhaust pipes and silencers
  520
• 1.1 Assembly overview – silencers
  520
• 1.2 Assembly overview - front exhaust pipe
  520
• 1.3 Removing and installing front exhaust pipe
  522
• 1.4 Removing and installing silencer
  523
• 1.5 Removing and installing front exhaust pipe bracket
  525
• 1.6 Aligning exhaust system free of stress
  526
• 1.7 Checking exhaust system for leaks
  527
• 1.8 Installation position of clamp
  527
• 1.9 Align end exhaust pipes
  529
• 2 Emission control
  530
• 2.1 Assembly overview – emission control
  530
• 2.2 Removing and installing catalytic converter
  534
• 2.3 Removing and installing particulate filter
  536
• 2.4 Removing and installing emission control module
  536
• 2.5 Removing and installing exhaust flap control unit J883
  547
• 3 SCR system (selective catalytic reduction)
  549
• 3.1 Assembly overview – reducing agent tank
  549
• 3.2 Assembly overview - reducing agent supply line
  551
• 3.3 Assembly overview - delivery module for reducing agent
  552
• 3.4 Removing and installing reducing agent tank
  553
• 3.5 Removing and installing front section of reducing agent supply line
  556
• 3.6 Removing and installing delivery module for reducing agent
  563
• 3.7 Removing and installing injector for reduction agent N474
  565
• 3.8 Removing and installing control unit for reducing-agent heater J891
  568
• 3.9 Assembly overview - injector for reducing agent
  568
• 3.10 Draining reducing agent tank
  570
• 3.11 Removing and installing rear section of reducing agent supply line
  573
• 3.12 Removing and installing filler pipe for reducing agent tank
  574
• 3.13 Disconnecting reducing agent supply line
  576
• 3.14 SCR - resetting learnt values
  579
• 4 Exhaust gas temperature regulation
  581
• 4.1 Assembly overview – exhaust gas temperature regulation
  581
• 4.2 Removing and installing exhaust gas temperature sender 1 G235
  583
• 4.3 Removing and installing exhaust gas temperature sender 2 G448
  588
• 4.4 Removing and installing exhaust gas temperature sender 3 G495
  590
• 4.5 Removing and installing exhaust gas temperature sender 4 G648
  592
• 5 Exhaust gas recirculation
  595
• 5.1 Assembly overview – exhaust gas recirculation
  595
• 5.2 Assembly overview - exhaust gas recirculation valve 1 GX5
  600
• 5.3 Removing and installing exhaust gas recirculation cooler
  601
• 5.4 Removing and installing exhaust gas recirculation valve 1 GX5
  609
• 5.5 Removing and installing exhaust gas recirculation valve 2 GX6
  610
• 5.6 Removing and installing exhaust gas recirculation temperature sensor G98
  611
• 5.7 Checking exhaust gas recirculation cooler for leaks
  615
• Glow plug system
  621
• 1 Glow plug system
  621
• 1.1 Assembly overview – glow plug system
  621
• 1.2 Removing and installing glow plug
  623
• 1.3 Removing and installing automatic glow period control unit J179
  626
• 1.4 Removing and installing Hall sender G40
  627
• 1.5 Removing and installing engine speed sender G28
  627