4-cyl. direct injection engine (1.8 l, 4 V, EA 888 Gen III, turbocharger, chain drive)

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 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 instructions
  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
  25
• 1.3 Securing engine on engine and gearbox support
  30
• 1.4 Installing engine
  33
• 2 Assembly mountings
  36
• 2.1 Assembly overview - assembly mountings
  36
• 2.2 Removing and installing engine mounting
  38
• 2.3 Removing and installing gearbox mounting
  40
• 2.4 Removing and installing pendulum support
  43
• 2.5 Supporting engine in installation position
  46
• 3 Engine cover panel
  51
• 3.1 Removing and installing engine cover
  51
• Crankshaft group
  52
• 1 Cylinder block (pulley end)
  52
• 1.1 Assembly overview - cylinder block (pulley end)
  52
• 1.2 Removing and installing poly-V belt
  55
• 1.3 Removing and installing tensioner for poly V-belt
  56
• 1.4 Removing and installing vibration damper
  57
• 1.5 Removing and installing bracket for ancillaries
  64
• 1.6 Renewing seal for vibration damper
  67
• 1.7 Removing and installing engine support
  70
• 2 Cylinder block, gearbox end
  72
• 2.1 Assembly overview - cylinder block, gearbox end
  72
• 2.2 Removing and installing flywheel
  73
• 2.3 Removing and installing sealing flange on gearbox side
  75
• 3 Crankshaft
  80
• 3.1 Assembly overview - crankshaft
  80
• 3.2 Crankshaft dimensions
  82
• 3.3 Allocation of main bearing shells
  82
• 3.4 Renewing needle bearing in crankshaft
  84
• 3.5 Measuring axial clearance of crankshaft
  86
• 3.6 Measuring radial clearance of crankshaft
  87
• 3.7 Removing and installing sender wheel
  88
• 4 Balancer shaft
  90
• 4.1 Assembly overview - balance shaft
  90
• 4.2 Removing and installing balance shaft
  91
• 4.3 Renewing oil seal for balance shaft (inlet side)
  96
• 5 Pistons and conrods
  98
• 5.1 Assembly overview - pistons and conrods
  98
• 5.2 Removing and installing pistons
  102
• 5.3 Removing and installing oil spray jets
  104
• 5.4 Checking pistons and cylinder bores
  105
• 5.5 Separating new conrod
  108
• 5.6 Checking radial clearance of conrods
  108
• Cylinder head, valve gear
  110
• 1 Cylinder head
  110
• 1.1 Assembly overview - cylinder head
  110
• 1.2 Removing and installing cylinder head
  113
• 1.3 Removing and installing vacuum pump
  120
• 1.4 Checking compression
  122
• 2 Cover for timing chain
  125
• 2.1 Assembly overview - cover for timing chain
  125
• 2.3 Removing and installing timing chain cover
  127
• 3 Chain drive
  134
• 3.1 Assembly overview - camshaft timing chains
  134
• 3.2 Removing and installing camshaft timing chain
  137
• 3.3 Assembly overview - drive chain for balance shaft
  153
• 3.4 Removing and installing drive chain for balance shaft
  156
• 3.5 Checking timing chain
  156
• 3.6 Checking valve timing
  157
• 4 Valve gear
  160
• 4.1 Assembly overview - valve gear
  160
• 4.2 Removing and installing camshaft
  165
• 4.3 Installing ball for sliding piece
  182
• 4.4 Removing and installing valve stem seals
  183
• 5 Inlet and exhaust valves
  194
• 5.1 Checking valve guides
  194
• 5.2 Checking valves
  195
• 5.3 Valve dimensions
  195
• Lubrication
  196
• 1 Sump, oil pump
  196
• 1.1 Assembly overview - sump/oil pump
  196
• 1.2 Removing and installing oil level and oil temperature sender G266
  199
• 1.3 Removing and installing lower part of sump
  200
• 1.4 Removing and installing oil pump
  206
• 1.5 Removing and installing upper part of sump
  209
• 1.6 Engine oil:
  215
• 2 Engine oil cooler
  216
• 2.1 Assembly overview - engine oil cooler
  216
• 2.2 Removing and installing engine oil cooler
  216
• 2.3 Removing and installing mechanical switching valve
  218
• 3 Crankcase ventilation
  219
• 3.1 Assembly overview - crankcase breather system
  219
• 3.2 Removing and installing oil separator
  220
• 4 Oil filter, oil pressure switch
  221
• 4.1 Assembly overview - oil filter
  221
• 4.2 Assembly overview - oil pressure switches/oil pressure control
  221
• 4.3 Removing and installing piston cooling jet control valve N522
  223
• 4.4 Removing and installing oil pressure regulating valve N428
  223
• 4.5 Removing and installing oil pressure switch
  225
• 4.6 Checking oil pressure
  229
• Cooling
  234
• 1 Cooling system/coolant
  234
• 1.1 Connection diagram - coolant hoses
  234
• 1.2 Draining and adding coolant
  237
• 1.3 Checking cooling system for leaks
  245
• 1.4 Flushing cooling system
  248
• 2 Coolant pump, regulation of cooling system
  272
• 2.1 Assembly overview - coolant pump, thermostat
  272
• 2.2 Assembly overview - electric coolant pump
  274
• 2.3 Assembly overview - coolant temperature sender
  276
• 2.4 Removing and installing toothed belt for coolant pump
  277
• 2.5 Removing and installing coolant pump
  280
• 2.6 Removing and installing auxiliary pump for heating V488
  284
• 2.7 Removing and installing coolant shut-off valve N82
  288
• 2.8 Removing and installing coolant valve for gearbox N488, vehicles with dual clutch gearbox
  290
• 2.9 Removing and installing actuator for engine temperature regulation N493
  292
• 2.10 Removing and installing coolant temperature sender G62
  294
• 2.11 Removing and installing radiator outlet coolant temperature sender G83
  296
• 3 Coolant pipes
  298
• 3.1 Assembly overview - coolant pipes
  298
• 3.2 Removing and installing front coolant pipe
  298
• 3.3 Removing and installing upper coolant pipes
  300
• 4 Radiator, radiator fan
  303
• 4.1 Assembly overview - radiator/radiator fan
  303
• 4.2 Removing and installing radiator
  304
• 4.3 Removing and installing radiator cowl with radiator fan
  308
• 4.4 Removing and installing radiator fan
  312
• Turbocharging/supercharging
  313
• 1 Turbocharger
  313
• 1.1 Assembly overview - turbocharger
  313
• 1.2 Removing and installing turbocharger
  317
• 1.3 Removing and installing charge pressure positioner V465
  321
• 1.4 Adjusting charge pressure positioner V465
  322
• 2 Charge air system
  325
• 2.1 Assembly overview - charge air system
  325
• 2.2 Assembly overview - charge-air hose connections
  327
• 2.3 Removing and installing charge air cooler
  329
• 2.4 Removing and installing charge pressure sender G31
  330
• 2.5 Checking charge air system for leaks
  331
• Mixture preparation - injection
  334
• 1 Injection system
  334
• 1.1 Overview of fitting locations - injection system
  334
• 2 Injectors
  343
• 2.1 Assembly overview - fuel rail with injectors
  343
• 2.2 Removing and installing fuel rail
  345
• 2.3 Removing and installing injectors
  346
• 2.4 Renewing seals on injectors
  352
• 2.5 Cleaning injectors
  355
• 3 Air filter
  357
• 3.1 Assembly overview - air filter housing
  357
• 3.2 Removing and installing air filter housing
  358
• 4 Intake manifold
  359
• 4.1 Assembly overview – intake manifold
  359
• 4.2 Removing and installing intake manifold
  361
• 4.3 Removing and installing throttle valve module GX3
  367
• 4.4 Cleaning throttle valve module
  369
• 5 Senders and sensors
  371
• 5.2 Removing and installing fuel pressure sender G247
  373
• 5.3 Checking fuel pressure sender G247
  376
• 5.4 Removing and installing fuel pressure sender for low-pressure G410
  379
• 5.5 Removing and installing intake manifold sender GX9
  380
• 6 Engine control unit
  381
• 6.1 Removing and installing engine control unit J623
  381
• 7 High-pressure pump
  383
• 7.1 Assembly overview - high-pressure pump
  383
• 7.2 Removing and installing high-pressure pump
  385
• 7.3 Removing and installing high-pressure pipe
  389
• 8 Lambda probe
  393
• 8.1 Assembly overview - Lambda probe
  393
• 8.2 Removing and installing Lambda probe
  394
• Exhaust system
  397
• 1 Exhaust pipes and silencers
  397
• 1.1 Assembly overview – silencers
  397
• 1.2 Separating exhaust pipes from silencers
  398
• 1.3 Aligning exhaust system free of stress
  399
• 1.4 Checking exhaust system for leaks
  400
• 2 Emission control
  401
• 2.1 Assembly overview – emission control
  401
• 2.2 Removing and installing catalytic converter
  403
• Ignition system
  408
• 1 Ignition system
  408
• 1.1 Assembly overview - ignition system
  408
• 1.2 Test data, spark plugs
  410
• 1.3 Removing and installing ignition coils with output stage
  410
• 1.4 Removing and installing knock sensor 1 G61
  413
• 1.5 Removing and installing Hall sender
  414
• 1.6 Removing and installing engine speed sender G28
  415