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

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 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
  5
• 3.1 Rules for cleanliness
  5
• 3.2 Foreign objects in engine
  5
• 3.3 Contact corrosion
  5
• 3.4 Routing and attachment of lines
  5
• 3.5 Fitting radiator and condensers
  6
• 3.6 Checking vacuum system
  6
• Removing and installing engine
  7
• 1 Removing and installing engine
  7
• 1.1 Removing engine
  7
• 1.2 Separating engine and gearbox
  16
• 1.3 Securing engine on engine and gearbox support
  20
• 1.4 Installing engine
  22
• 2 Assembly mountings
  25
• 2.1 Assembly overview - assembly mountings
  25
• 2.2 Removing and installing engine mounting
  27
• 2.3 Removing and installing gearbox mounting
  28
• 2.4 Removing and installing pendulum support
  30
• 2.5 Supporting engine in installation position
  31
• 2.6 Adjusting assembly mountings
  35
• 2.7 Checking adjustment of assembly mountings
  37
• 3 Engine cover panel
  38
• 3.1 Removing and installing engine cover
  38
• Crankshaft group
  39
• 1 Cylinder block (pulley end)
  39
• 1.1 Assembly overview - cylinder block (pulley end)
  39
• 1.2 Removing and installing poly-V belt
  42
• 1.3 Removing and installing tensioner for poly V-belt
  42
• 1.4 Removing and installing vibration damper
  43
• 1.5 Removing and installing bracket for ancillaries
  50
• 1.6 Removing and installing engine support
  53
• 1.7 Renewing crankshaft oil seal - belt pulley end
  54
• 2 Cylinder block, gearbox end
  57
• 2.1 Assembly overview - cylinder block, gearbox end
  57
• 2.2 Removing and installing flywheel
  58
• 2.3 Removing and installing sealing flange on gearbox side
  60
• 3 Crankshaft
  65
• 3.1 Assembly overview - crankshaft
  65
• 3.2 Crankshaft dimensions
  68
• 3.3 Allocation of main bearing shells
  68
• 3.4 Renewing needle bearing in crankshaft
  70
• 3.5 Measuring axial clearance of crankshaft
  72
• 3.6 Measuring radial clearance of crankshaft
  73
• 3.7 Removing and installing sender wheel
  74
• 4 Balancer shaft
  76
• 4.1 Assembly overview - balance shaft
  76
• 4.2 Removing and installing balance shaft
  78
• 4.3 Renewing oil seal for balance shaft (inlet side)
  83
• 5 Pistons and conrods
  86
• 5.1 Assembly overview - pistons and conrods
  86
• 5.2 Removing and installing pistons
  90
• 5.3 Checking pistons and cylinder bores
  92
• 5.4 Separating new conrod
  94
• 5.5 Checking radial clearance of conrods
  95
• 5.6 Removing and installing oil spray jets
  95
• Cylinder head, valve gear
  97
• 1 Cylinder head
  97
• 1.1 Assembly overview - cylinder head
  97
• 1.2 Assembly overview - vacuum pump
  100
• 1.3 Removing and installing cylinder head
  101
• 1.4 Removing and installing vacuum pump
  107
• 1.5 Checking compression
  110
• 2 Cover for timing chain
  112
• 2.1 Assembly overview - cover for timing chain
  112
• 2.2 Removing and installing timing chain cover
  115
• 3 Chain drive
  124
• 3.1 Assembly overview - camshaft timing chains
  124
• 3.2 Assembly overview - drive chain for balance shaft
  125
• 3.3 Removing and installing camshaft timing chain
  127
• 3.4 Removing and installing drive chain for balance shaft
  145
• 3.5 Checking valve timing
  145
• 3.6 Checking timing chain
  148
• 4 Valve gear
  150
• 4.1 Assembly overview - valve gear
  150
• 4.2 Removing and installing camshaft
  155
• 4.3 Removing and installing camshaft control valve 1 N205
  173
• 4.4 Removing and installing exhaust camshaft control valve 1 N318
  173
• 4.5 Removing and installing valve stem seals
  174
• 4.6 Installing ball for sliding piece
  184
• 4.7 Removing and installing actuators for camshaft adjustment
  186
• 5 Inlet and exhaust valves
  187
• 5.1 Checking valve guides
  187
• 5.2 Checking valves
  188
• 5.3 Valve dimensions
  188
• Lubrication
  189
• 1 Sump, oil pump
  189
• 1.1 Assembly overview - sump/oil pump
  189
• 1.2 Engine oil:
  192
• 1.3 Removing and installing lower part of sump
  192
• 1.4 Removing and installing upper part of sump
  193
• 1.5 Removing and installing oil pump
  197
• 1.6 Removing and installing oil level and oil temperature sender G266
  200
• 2 Engine oil cooler
  201
• 2.1 Assembly overview - engine oil cooler
  201
• 2.2 Removing and installing engine oil cooler
  201
• 2.3 Removing and installing mechanical switching valve
  203
• 3 Crankcase ventilation
  204
• 3.1 Assembly overview - crankcase breather system
  204
• 3.2 Removing and installing oil separator
  205
• 4 Oil filter, oil pressure switch
  206
• 4.1 Assembly overview - oil filter
  206
• 4.2 Assembly overview - oil pressure switches/oil pressure control
  206
• 4.3 Removing and installing oil pressure switch
  208
• 4.4 Checking oil pressure
  211
• 4.5 Removing and installing oil pressure regulating valve N428
  213
• 4.6 Removing and installing piston cooling jet control valve N522
  214
• Cooling
  216
• 1 Cooling system/coolant
  216
• 1.1 Connection diagram - coolant hoses
  216
• 1.2 Checking cooling system for leaks
  220
• 1.3 Draining and adding coolant
  223
• 1.4 Flushing cooling system
  230
• 2 Coolant pump, regulation of cooling system
  254
• 2.1 Assembly overview - coolant pump, thermostat
  254
• 2.2 Assembly overview - electric coolant pump
  256
• 2.3 Assembly overview - coolant temperature sender
  258
• 2.4 Removing and installing coolant pump
  259
• 2.5 Removing and installing toothed belt for coolant pump
  261
• 2.6 Removing and installing coolant temperature sender G62
  263
• 2.7 Removing and installing radiator outlet coolant temperature sender G83
  265
• 2.8 Removing and installing coolant valves
  266
• 2.9 Removing and installing actuator for engine temperature regulation N493
  269
• 2.10 Removing and installing auxiliary pump for heating V488
  271
• 3 Coolant pipes
  273
• 3.1 Assembly overview - coolant pipes
  273
• 3.2 Removing and installing upper coolant pipes
  273
• 3.3 Removing and installing front coolant pipe
  275
• 4 Radiator, radiator fan
  277
• 4.1 Assembly overview – radiator
  277
• 4.2 Assembly overview - auxiliary radiator
  278
• 4.3 Assembly overview – radiator cowl and radiator fan
  280
• 4.4 Removing and installing radiator
  281
• 4.5 Removing and installing radiator cowl
  283
• 4.6 Removing and installing radiator fan
  284
• 4.7 Removing and installing auxiliary radiator
  285
• Turbocharging/supercharging
  291
• 1 Turbocharger
  291
• 1.1 Assembly overview - turbocharger
  291
• 1.2 Removing and installing turbocharger
  296
• 1.3 Removing and installing charge pressure positioner V465
  303
• 1.4 Adjusting charge pressure positioner V465
  304
• 2 Charge air system
  308
• 2.1 Assembly overview - charge air system
  308
• 2.2 Removing and installing charge air cooler
  309
• 2.3 Removing and installing charge pressure sender G31
  312
• 2.4 Checking charge air system for leaks
  312
• 2.5 Removing and installing air pipe
  315
• Mixture preparation - injection
  319
• 1 Injection system
  319
• 1.1 Overview of fitting locations - injection system
  319
• 2 Injectors
  328
• 2.1 Assembly overview - fuel rail
  328
• 2.2 Removing and installing fuel rail
  329
• 2.3 Removing and installing injectors
  329
• 2.4 Renewing seals on injectors
  332
• 2.5 Cleaning injectors
  336
• 3 Air filter
  339
• 3.1 Assembly overview - air filter housing
  339
• 3.2 Removing and installing air filter housing
  340
• 3.3 Removing and installing air guide on lock carrier
  341
• 4 Intake manifold
  343
• 4.1 Assembly overview – intake manifold
  343
• 4.2 Removing and installing intake manifold
  345
• 4.3 Removing and installing throttle valve module GX3
  351
• 4.4 Cleaning throttle valve module GX3
  352
• 5 Senders and sensors
  354
• 5.2 Removing and installing fuel pressure sender G247
  355
• 5.3 Checking fuel pressure sender G247
  357
• 5.4 Removing and installing air mass meter G70
  359
• 5.5 Removing and installing intake manifold sender GX9
  361
• 5.6 Removing and installing pressure differential sender for particulate filter G1037
  361
• 5.7 Removing and installing actuator for structure-borne sound R214
  362
• 6 Engine control unit
  364
• 6.1 Removing and installing engine control unit J623
  364
• 6.2 Removing and installing engine (motor) control unit J623 with protective housing
  364
• 7 High-pressure pump
  368
• 7.1 Assembly overview - high-pressure pump
  368
• 7.2 Removing and installing high-pressure pump
  368
• 7.3 Removing and installing high-pressure pipe
  371
• 8 Lambda probe
  374
• 8.1 Assembly overview - Lambda probe
  374
• 8.2 Removing and installing Lambda probe
  374
• Exhaust system
  378
• 1 Exhaust pipes and silencers
  378
• 1.1 Assembly overview – silencers
  378
• 1.2 Separating exhaust pipes from silencers
  379
• 1.3 Removing and installing silencer
  381
• 1.4 Aligning exhaust system free of stress
  382
• 1.5 Checking exhaust system for leaks
  383
• 1.6 Installation position of clamp
  383
• 2 Emission control
  385
• 2.1 Assembly overview – emission control
  385
• 2.2 Assembly overview - pressure differential sender
  388
• 2.3 Removing and installing exhaust pipe with catalytic converter and particulate filter
  388
• 2.5 Removing and installing exhaust flap control unit J883/J945
  394
• 3 Exhaust gas temperature regulation
  395
• 3.1 Assembly overview – exhaust gas temperature regulation
  395
• 3.2 Removing and installing parts of exhaust gas temperature regulation
  395
• Ignition system
  399
• 1 Ignition system
  399
• 1.1 Assembly overview - ignition system
  399
• 1.2 Removing and installing ignition coils with output stage
  401
• 1.3 Removing and installing knock sensor 1 G61
  403
• 1.4 Removing and installing Hall sender
  404
• 1.5 Removing and installing engine speed sender G28
  406