4-cyl. direct injection engine (1.8 l, 2.0 l, 4 V, turbocharger, chain drive, EA888, generation III)

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
  1
• 1.4 Safety precautions when working on the cooling system
  2
• 1.5 Safety precautions when working on ignition system
  2
• 2 Identification
  3
• 2.1 Engine number/engine data
  3
• 3 Repair instructions
  6
• 3.1 Rules for cleanliness
  6
• 3.2 General notes
  6
• 3.3 General repair notes
  6
• 3.4 Foreign objects in engine
  7
• 3.5 Contact corrosion
  7
• 3.6 Routing and attachment of lines
  7
• 3.7 Fitting radiator and condensers
  7
• 3.8 Checking vacuum system
  7
• Removing and installing engine
  9
• 1 Removing and installing engine
  9
• 1.1 Removing engine
  9
• 1.2 Separating engine and gearbox
  25
• 1.3 Securing engine on engine and gearbox support
  31
• 1.4 Installing engine
  33
• 2 Assembly mountings
  37
• 2.1 Assembly overview - assembly mountings
  37
• 2.2 Removing and installing engine mounting
  39
• 2.3 Removing and installing gearbox mounting
  39
• 2.4 Removing and installing pendulum support
  41
• 2.5 Supporting engine in installation position
  42
• 2.6 Adjusting assembly mountings
  46
• 2.7 Checking adjustment of assembly mountings
  47
• 3 Engine cover panel
  49
• 3.1 Removing and installing engine cover
  49
• Crankshaft group
  50
• 1 Cylinder block (pulley end)
  50
• 1.1 Assembly overview - cylinder block (pulley end)
  50
• 1.2 Removing and installing poly-V belt
  53
• 1.3 Removing and installing tensioner for poly V-belt
  55
• 1.4 Removing and installing vibration damper
  55
• 1.5 Removing and installing bracket for ancillaries
  62
• 1.6 Removing and installing engine support
  65
• 2 Cylinder block, gearbox end
  67
• 2.1 Assembly overview - cylinder block, gearbox end
  67
• 2.2 Assembly overview - drive plate
  68
• 2.3 Removing and installing drive plate
  68
• 2.4 Removing and installing flywheel
  71
• 2.5 Removing and installing sealing flange on gearbox side
  72
• 3 Crankshaft
  78
• 3.1 Assembly overview - crankshaft
  78
• 3.2 Crankshaft dimensions
  80
• 3.3 Allocation of main bearing shells
  80
• 3.4 Renewing needle bearing in crankshaft
  82
• 3.5 Measuring axial clearance of crankshaft
  85
• 3.6 Measuring radial clearance of crankshaft
  86
• 3.7 Removing and installing sender wheel
  87
• 4 Balancer shaft
  89
• 4.1 Assembly overview - balance shaft
  89
• 4.2 Removing and installing balance shaft
  90
• 4.3 Renewing oil seal for balance shaft (inlet side)
  95
• 5 Pistons and conrods
  97
• 5.1 Assembly overview - pistons and conrods
  97
• 5.2 Removing and installing pistons
  99
• 5.3 Checking pistons and cylinder bores
  100
• 5.4 Separating new conrod
  105
• 5.5 Checking radial clearance of conrods
  106
• Cylinder head, valve gear
  107
• 1 Cylinder head
  107
• 1.1 Assembly overview - cylinder head
  107
• 1.2 Assembly overview - camshaft housing
  110
• 1.3 Removing and installing cylinder head
  112
• 1.4 Removing and installing vacuum pump
  119
• 1.5 Checking compression
  121
• 2 Cover for timing chain
  124
• 2.1 Assembly overview - cover for timing chain
  124
• 2.2 Removing and installing timing chain cover
  128
• 2.3 Renewing seal for vibration damper
  135
• 3 Chain drive
  138
• 3.1 Assembly overview - camshaft timing chains
  138
• 3.2 Assembly overview - drive chain for balance shaft
  145
• 3.3 Removing and installing camshaft timing chain
  148
• 3.4 Removing and installing drive chain for balance shaft
  182
• 3.5 Checking chain elongation
  182
• 3.6 Checking valve timing
  183
• 4 Valve gear
  186
• 4.1 Assembly overview - valve gear
  186
• 4.2 Removing and installing camshaft
  189
• 4.3 Removing and installing camshaft control valve 1 N205
  223
• 4.5 Installing ball for sliding piece
  224
• 4.6 Removing and installing valve stem seals
  225
• 5 Inlet and exhaust valves
  236
• 5.1 Checking valve guides
  236
• 5.2 Checking valves
  237
• 5.3 Valve dimensions
  237
• Lubrication
  238
• 1 Sump, oil pump
  238
• 1.1 Assembly overview - sump/oil pump
  238
• 1.2 Engine oil:
  241
• 1.3 Removing and installing lower part of sump
  242
• 1.4 Removing and installing upper part of sump
  246
• 1.5 Removing and installing oil pump
  251
• 1.6 Removing and installing oil level and oil temperature sender G266
  254
• 2 Engine oil cooler
  256
• 2.1 Assembly overview - engine oil cooler
  256
• 2.2 Removing and installing engine oil cooler
  256
• 2.3 Removing and installing mechanical switching valve
  258
• 3 Crankcase ventilation
  259
• 3.1 Assembly overview - crankcase breather system
  259
• 3.2 Removing and installing oil separator
  260
• 4 Oil filter, oil pressure switch
  261
• 4.1 Assembly overview - oil filter
  261
• 4.2 Assembly overview - oil pressure switches/oil pressure control
  261
• 4.3 Removing and installing oil pressure switch F1
  263
• 4.4 Removing and installing oil pressure switch for reduced oil pressure F378
  264
• 4.5 Removing and installing stage 3 oil pressure switch F447
  265
• 4.6 Checking oil pressure
  267
• 4.7 Removing and installing piston cooling jet control valve N522
  271
• 4.8 Removing and installing oil pressure regulating valve N428
  271
• Cooling
  273
• 1 Cooling system/coolant
  273
• 1.1 Connection diagram - coolant hoses
  273
• 1.2 Checking cooling system for leaks
  280
• 1.3 Draining and adding coolant
  283
• 2 Coolant pump, regulation of cooling system
  291
• 2.1 Assembly overview - coolant pump, thermostat
  291
• 2.2 Assembly overview - electric coolant pump
  293
• 2.3 Assembly overview – coolant valves
  295
• 2.4 Assembly overview - coolant temperature sender
  298
• 2.5 Removing and installing electric coolant pump
  299
• 2.6 Removing and installing coolant valves
  305
• 2.7 Removing and installing coolant pump
  312
• 2.8 Removing and installing toothed belt for coolant pump
  316
• 2.9 Removing and installing actuator for engine temperature regulation N493
  318
• 2.10 Removing and installing coolant temperature sender G62
  321
• 2.11 Removing and installing radiator outlet coolant temperature sender G83
  322
• 3 Coolant pipes
  324
• 3.1 Assembly overview - coolant pipes
  324
• 3.2 Removing and installing front coolant pipes
  324
• 3.3 Removing and installing upper coolant pipes
  326
• 3.4 Removing and installing coolant pipes for gearbox
  327
• 4 Radiator, radiator fan
  330
• 4.1 Assembly overview - radiator/radiator fan
  330
• 4.2 Assembly overview - auxiliary radiator
  332
• 4.3 Assembly overview – radiator cowl and radiator fan
  333
• 4.4 Removing and installing radiator
  334
• 4.5 Removing and installing radiator cowl
  336
• 4.6 Removing and installing radiator fan
  338
• 4.7 Removing and installing auxiliary radiator
  339
• Turbocharging/supercharging
  342
• 1 Turbocharger
  342
• 1.1 Assembly overview - turbocharger
  342
• 1.2 Removing and installing turbocharger
  345
• 1.3 Adjusting charge pressure positioner V465
  351
• 1.4 Removing and installing turbocharger air recirculation valve N249
  353
• 2 Charge air system
  354
• 2.1 Assembly overview - charge air system
  354
• 2.2 Assembly overview - charge-air hose connections
  356
• 2.3 Removing and installing charge air cooler
  356
• 2.4 Removing and installing charge pressure sender G31
  359
• 2.5 Checking charge air system for leaks
  360
• 2.6 Removing and installing air pipe
  362
• Mixture preparation - injection
  365
• 1 Injection system
  365
• 1.1 Overview of fitting locations - injection system
  365
• 1.2 Releasing high pressure in fuel system
  380
• 2 Injectors
  382
• 2.1 Assembly overview - fuel rail with injectors
  382
• 2.2 Removing and installing fuel rail
  384
• 2.3 Removing and installing injectors
  385
• 2.4 Renewing seals on injectors
  393
• 2.5 Cleaning injectors
  396
• 3 Air filter
  398
• 3.1 Assembly overview - air filter housing
  398
• 3.2 Removing and installing air filter housing
  400
• 3.3 Removing and installing air guide on lock carrier
  402
• 4 Intake manifold
  404
• 4.1 Assembly overview – intake manifold
  404
• 4.2 Assembly overview - lower part of intake manifold with fuel rail
  406
• 4.3 Removing and installing intake manifold
  411
• 4.4 Removing and installing throttle valve module GX3
  418
• 4.5 Cleaning throttle valve module
  420
• 4.6 Checking intake manifold change-over
  421
• 5 Senders and sensors
  424
• 5.2 Removing and installing fuel pressure sender G247
  426
• 5.3 Checking fuel pressure sender G247
  428
• 5.4 Removing and installing fuel pressure sender for low-pressure G410
  431
• 5.5 Removing and installing intake manifold sender GX9
  433
• 6 Engine control unit
  435
• 6.1 Assembly overview – engine/motor control unit
  435
• 6.2 Removing and installing engine control unit J623
  435
• 7 High-pressure pump
  441
• 7.1 Assembly overview - high-pressure pump
  441
• 7.2 Removing and installing high-pressure pump
  443
• 7.3 Removing and installing high-pressure pipe
  448
• 8 Lambda probe
  452
• 8.1 Assembly overview - Lambda probe
  452
• 8.2 Removing and installing Lambda probe 1 before catalytic converter GX10
  453
• 8.3 Removing and installing Lambda probe 1 after catalytic converter GX7
  454
• Exhaust system
  457
• 1 Exhaust pipes and silencers
  457
• 1.1 Assembly overview – silencers
  457
• 1.2 Separating exhaust pipes from silencers
  460
• 1.3 Removing and installing silencer
  462
• 1.4 Aligning exhaust system free of stress
  466
• 1.5 Checking exhaust system for leaks
  467
• 1.6 Installation position of clamp
  467
• 2 Emission control
  469
• 2.1 Assembly overview – emission control
  469
• 2.2 Removing and installing catalytic converter
  474
• 2.3 Removing and installing particulate filter
  480
• 3 Secondary air system
  481
• 3.1 Assembly overview - secondary air system
  481
• 3.2 Removing and installing secondary air pump motor V101
  482
• 3.3 Removing and installing secondary air inlet valve N112
  482
• Ignition system
  485
• 1 Ignition system
  485
• 1.1 Assembly overview - ignition system
  485
• 1.2 Test data, spark plugs
  487
• 1.3 Removing and installing ignition coils with output stage
  487
• 1.4 Removing and installing knock sensor 1 G61
  489
• 1.5 Removing and installing Hall sender
  490
• 1.6 Removing and installing engine speed sender G28
  491