4-cyl. direct injection engine (2.0 l, 4 V, EA 888 gen III BZ, turbocharger, chain drive)

Kapitelübersicht

• 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 ignition system
  2
• 1.5 Safety precautions when working on the cooling system
  2
• 1.6 Safety precautions when working on exhaust system
  3
• 2 Identification
  4
• 2.1 Engine number/engine data
  4
• 3 Repair notes
  6
• 3.1 Rules for cleanliness
  6
• 3.2 Foreign objects in engine
  6
• 3.3 Contact corrosion
  6
• 3.4 Routing and attachment of lines
  6
• 3.5 Fitting radiator and condensers
  7
• 3.6 Checking vacuum system
  7
• Removing and installing engine
  8
• 1 Removing and installing engine
  8
• 1.1 Removing engine
  8
• 1.2 Separating engine and gearbox
  24
• 1.3 Securing engine on engine and gearbox support
  34
• 1.4 Installing engine
  37
• 2 Assembly mountings
  41
• 2.1 Assembly overview - assembly mountings
  41
• 2.2 Removing and installing engine mounting
  43
• 2.3 Removing and installing gearbox mounting
  44
• 2.4 Removing and installing pendulum support
  46
• 2.5 Supporting engine in installation position
  48
• 2.6 Checking adjustment of assembly mountings
  69
• 2.7 Adjusting assembly mountings
  69
• 3 Engine cover panel
  72
• 3.1 Removing and installing engine cover
  72
• Crankshaft group
  73
• 1 Cylinder block (pulley end)
  73
• 1.1 Assembly overview - cylinder block (pulley end)
  73
• 1.2 Removing and installing poly-V belt
  76
• 1.3 Removing and installing tensioner for poly V-belt
  77
• 1.4 Removing and installing vibration damper
  78
• 1.5 Renewing seal for vibration damper
  85
• 1.6 Removing and installing bracket for ancillaries
  88
• 1.7 Removing and installing engine support
  90
• 2 Cylinder block, gearbox end
  93
• 2.1 Assembly overview - cylinder block, gearbox end
  93
• 2.2 Removing and installing flywheel
  94
• 2.3 Removing and installing sealing flange on gearbox side
  96
• 3 Crankshaft
  101
• 3.1 Assembly overview - crankshaft
  101
• 3.2 Crankshaft dimensions
  104
• 3.3 Allocation of main bearing shells
  104
• 3.4 Renewing needle bearing in crankshaft
  106
• 3.5 Measuring axial clearance of crankshaft
  108
• 3.6 Measuring radial clearance of crankshaft
  109
• 3.7 Removing and installing sender wheel
  110
• 4 Balancer shaft
  112
• 4.1 Assembly overview - balance shaft
  112
• 4.2 Removing and installing balance shaft
  114
• 5 Pistons and conrods
  121
• 5.1 Assembly overview - pistons and conrods
  121
• 5.2 Removing and installing pistons
  125
• 5.3 Checking pistons and cylinder bores
  127
• 5.4 Separating new conrod
  129
• 5.5 Checking radial clearance of conrods
  129
• 5.6 Removing and installing oil spray jets
  130
• Cylinder head, valve gear
  132
• 1 Cylinder head
  132
• 1.1 Assembly overview - cylinder head
  132
• 1.2 Removing and installing cylinder head
  135
• 1.3 Assembly overview - vacuum pump
  141
• 1.4 Removing and installing vacuum pump
  142
• 1.5 Checking compression
  144
• 2 Cover for timing chain
  147
• 2.1 Assembly overview - cover for timing chain
  147
• 2.2 Removing and installing timing chain cover
  150
• 3 Chain drive
  157
• 3.1 Assembly overview - camshaft timing chains
  157
• 3.2 Assembly overview - drive chain for balance shaft
  160
• 3.3 Removing and installing camshaft timing chain
  162
• 3.4 Removing and installing drive chain for balance shaft
  175
• 3.5 Checking timing chain
  178
• 4 Valve gear
  180
• 4.1 Assembly overview - valve gear
  180
• 4.2 Removing and installing camshaft
  184
• 4.3 Removing and installing actuators for camshaft adjustment
  195
• 4.4 Removing and installing camshaft control valve 1 N205
  197
• 4.5 Removing and installing exhaust camshaft control valve 1 N318
  197
• 4.6 Removing and installing valve stem seals
  198
• 5 Inlet and exhaust valves
  209
• 5.1 Checking valve guides
  209
• 5.2 Checking valves
  210
• 5.3 Valve dimensions
  210
• Lubrication
  211
• 1 Sump, oil pump
  211
• 1.1 Assembly overview - sump/oil pump
  211
• 1.2 Engine oil:
  214
• 1.3 Removing and installing lower part of sump
  214
• 1.4 Removing and installing upper part of sump
  220
• 1.5 Removing and installing oil pump
  226
• 1.6 Removing and installing oil level and oil temperature sender G266
  229
• 2 Engine oil cooler
  231
• 2.1 Assembly overview - engine oil cooler
  231
• 2.2 Removing and installing engine oil cooler
  231
• 3 Crankcase ventilation
  234
• 3.1 Assembly overview - crankcase breather system
  234
• 3.2 Removing and installing oil separator
  235
• 4 Oil filter, oil pressure switch
  237
• 4.1 Assembly overview - oil filter
  237
• 4.2 Assembly overview - oil pressure switches/oil pressure control
  237
• 4.3 Removing and installing piston cooling jet control valve N522
  239
• 4.4 Removing and installing oil pressure switch
  240
• 4.5 Checking oil pressure
  244
• 4.6 Removing and installing oil pressure regulating valve N428
  248
• Cooling
  250
• 1 Cooling system/coolant
  250
• 1.1 Connection diagram - coolant hoses
  250
• 1.2 Checking cooling system for leaks
  252
• 1.3 Draining and adding coolant
  256
• 1.4 Flushing cooling system
  264
• 2 Coolant pump, regulation of cooling system
  288
• 2.1 Assembly overview - coolant pump, thermostat
  288
• 2.2 Assembly overview - electric coolant pump
  290
• 2.3 Assembly overview - coolant temperature sender
  293
• 2.4 Removing and installing electric coolant pump
  294
• 2.5 Removing and installing coolant pump
  297
• 2.6 Removing and installing toothed belt for coolant pump
  300
• 2.7 Removing and installing coolant valves
  301
• 2.8 Removing and installing actuator for engine temperature regulation N493
  306
• 2.9 Removing and installing coolant temperature sender G62
  309
• 2.10 Removing and installing radiator outlet coolant temperature sender G83
  310
• 3 Coolant pipes
  312
• 3.1 Assembly overview - coolant pipes
  312
• 3.2 Removing and installing coolant pipes
  312
• 3.3 Removing and installing upper coolant pipes
  314
• 4 Radiator, radiator fan
  316
• 4.1 Assembly overview – radiator
  316
• 4.2 Assembly overview – radiator cowl and radiator fan
  320
• 4.3 Removing and installing radiator
  322
• 4.4 Removing and installing radiator cowl
  329
• 4.5 Removing and installing radiator fan
  335
• Turbocharging/supercharging
  338
• 1 Turbocharger
  338
• 1.1 Assembly overview - turbocharger
  338
• 1.2 Removing and installing turbocharger
  342
• 2 Charge air system
  348
• 2.1 Assembly overview - charge air system
  348
• 2.2 Assembly overview - charge-air hose connections
  351
• 2.3 Removing and installing charge air cooler
  351
• 2.4 Removing and installing charge pressure sender G31
  356
• 2.5 Checking charge air system for leaks
  357
• Mixture preparation - injection
  361
• 1 Injection system
  361
• 1.1 Overview of fitting locations - injection system
  361
• 2 Injectors
  373
• 2.1 Assembly overview - fuel rail with injectors
  373
• 2.2 Removing and installing fuel rail
  375
• 2.3 Removing and installing injectors
  376
• 2.4 Renewing seals on injectors
  383
• 2.5 Cleaning injectors
  386
• 3 Air filter
  388
• 3.1 Assembly overview - air filter housing
  388
• 3.2 Removing and installing air filter housing
  391
• 3.3 Removing and installing air guide on lock carrier
  393
• 4 Intake manifold
  396
• 4.1 Assembly overview – intake manifold
  396
• 4.2 Removing and installing intake manifold
  398
• 4.3 Removing and installing throttle valve module GX3
  403
• 4.4 Cleaning throttle valve module GX3
  406
• 4.5 Checking intake manifold change-over
  407
• 5 Senders and sensors
  409
• 5.1 Removing and installing fuel pressure sender G247
  409
• 5.2 Checking fuel pressure sender G247
  412
• 5.3 Removing and installing fuel pressure sender for low-pressure G410
  414
• 5.4 Removing and installing intake manifold sender GX9
  415
• 5.5 Removing and installing air mass meter G70
  416
• 5.7 Removing and installing pressure differential sender for particulate filter G1037
  420
• 6 Engine control unit
  422
• 6.1 Removing and installing engine control unit J623
  422
• 6.2 Removing and installing engine (motor) control unit J623 with protective housing
  423
• 7 High-pressure pump
  427
• 7.1 Assembly overview - high-pressure pump
  427
• 7.2 Removing and installing high-pressure pump
  429
• 7.3 Removing and installing high-pressure pipe
  432
• 8 Lambda probe
  436
• 8.1 Assembly overview - Lambda probe
  436
• 8.2 Removing and installing Lambda probe
  437
• Exhaust system
  441
• 1 Exhaust pipes and silencers
  441
• 1.1 Assembly overview – silencers
  441
• 1.2 Removing and installing silencer
  446
• 1.3 Separating exhaust pipes from silencers
  453
• 1.4 Aligning exhaust system free of stress
  459
• 1.5 Checking exhaust system for leaks
  459
• 2 Emission control
  460
• 2.1 Assembly overview – emission control
  460
• 2.3 Removing and installing catalytic converter
  471
• 3 Exhaust gas temperature regulation
  492
• 3.1 Assembly overview – exhaust gas temperature regulation
  492
• 3.2 Removing and installing parts of exhaust gas temperature regulation
  493
• Ignition system
  498
• 1 Ignition system
  498
• 1.1 Assembly overview - ignition system
  498
• 1.2 Removing and installing ignition coils with output stage
  500
• 1.3 Removing and installing knock sensor 1 G61
  502
• 1.4 Removing and installing Hall sender
  503
• 1.5 Removing and installing engine speed sender G28
  504