4-cyl. direct injection engine (2.0 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
• 2 Identification
  3
• 2.1 Engine number/engine data
  3
• 3 Repair instructions
  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 motor
  7
• 1.1 Removing motor
  7
• 1.2 Securing engine on engine and gearbox support
  24
• 1.3 Installing engine
  26
• 2 Assembly mountings
  30
• 2.1 Assembly overview - assembly mountings
  30
• 2.2 Supporting engine in installation position
  32
• 2.3 Removing and installing engine mounting
  34
• 2.4 Removing and installing support bearing
  37
• 2.5 Removing and installing gearbox mountings
  38
• Crankshaft group
  40
• 1 Cylinder block (pulley end)
  40
• 1.1 Assembly overview - cylinder block (pulley end)
  40
• 1.2 Removing and installing poly-V belt
  43
• 1.3 Removing and installing tensioner for poly V-belt
  44
• 1.4 Removing and installing vibration damper
  44
• 1.5 Removing and installing bracket for ancillaries
  52
• 1.6 Removing and installing engine support
  55
• 2 Cylinder block, gearbox end
  58
• 2.1 Assembly overview - cylinder block, gearbox end
  58
• 2.2 Removing and installing drive plate
  59
• 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 Measuring axial clearance of crankshaft
  70
• 3.5 Measuring radial clearance of crankshaft
  71
• 3.6 Removing and installing sender wheel
  72
• 4 Balancer shaft
  74
• 4.1 Assembly overview - balance shaft
  74
• 4.2 Removing and installing balance shaft
  76
• 4.3 Renewing oil seal for balance shaft (inlet side)
  81
• 5 Pistons and conrods
  84
• 5.1 Assembly overview - pistons and conrods
  84
• 5.2 Removing and installing pistons
  88
• 5.3 Checking pistons and cylinder bores
  90
• 5.4 Separating new conrod
  92
• 5.5 Checking radial clearance of conrods
  93
• 5.6 Removing and installing oil spray jets
  93
• Cylinder head, valve gear
  96
• 1 Cylinder head
  96
• 1.1 Assembly overview - cylinder head
  96
• 1.2 Removing and installing cylinder head
  99
• 1.3 Removing and installing vacuum pump
  105
• 1.4 Checking compression
  107
• 2 Cover for timing chain
  110
• 2.1 Assembly overview - cover for timing chain
  110
• 2.2 Removing and installing timing chain cover
  113
• 2.3 Renewing seal for vibration damper
  118
• 3 Chain drive
  121
• 3.1 Assembly overview - camshaft timing chains
  121
• 3.2 Assembly overview - drive chain for balance shaft
  123
• 3.3 Removing and installing bearing saddle
  126
• 3.4 Removing and installing camshaft timing chain
  131
• 3.5 Checking timing chain
  147
• 3.6 Checking valve timing
  148
• 4 Valve gear
  152
• 4.1 Assembly overview - valve gear
  152
• 4.2 Removing and installing camshaft
  157
• 4.3 Installing ball for sliding piece
  179
• 4.4 Removing and installing actuators for camshaft adjustment
  180
• 4.5 Removing and installing camshaft control valve 1 N205
  181
• 4.6 Removing and installing valve stem seals
  182
• 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 Engine oil:
  199
• 1.3 Check engine oil level withoil gauge tester T40178
  199
• 1.4 Removing and installing lower part of sump
  201
• 1.5 Removing and installing oil pump
  203
• 1.6 Removing and installing upper part of sump
  205
• 1.7 Removing and installing oil level and oil temperature sender G266
  210
• 2 Engine oil cooler
  211
• 2.1 Assembly overview - engine oil cooler
  211
• 2.2 Removing and installing engine oil cooler
  211
• 2.3 Removing and installing mechanical switching valve
  212
• 3 Crankcase ventilation
  214
• 3.1 Assembly overview - crankcase breather system
  214
• 3.2 Removing and installing oil separator
  215
• 4 Oil filter, oil pressure switch
  216
• 4.1 Assembly overview - oil filter
  216
• 4.2 Assembly overview - oil pressure switches/oil pressure control
  216
• 4.3 Removing and installing oil pressure switch F22
  218
• 4.4 Removing and installing oil pressure switch for reduced oil pressure F378
  218
• 4.5 Removing and installing stage 3 oil pressure switch F447
  219
• 4.6 Removing and installing oil pressure regulating valve N428
  220
• 4.7 Removing and installing piston cooling jet control valve N522
  221
• 4.8 Checking oil pressure
  221
• Cooling
  225
• 1 Cooling system/coolant
  225
• 1.1 Connection diagram - coolant hoses
  225
• 1.2 Overview of fitting locations – cooling system
  227
• 1.3 Checking cooling system for leaks
  229
• 1.4 Draining and adding coolant
  234
• 2 Coolant pump, regulation of cooling system
  243
• 2.1 Assembly overview - coolant pump, thermostat
  243
• 2.2 Assembly overview - electric coolant pump
  245
• 2.3 Assembly overview - coolant temperature sender
  246
• 2.4 Assembly overview - coolant valves
  247
• 2.5 Removing and installing electric coolant pump
  249
• 2.6 Removing and installing coolant pump
  253
• 2.7 Removing and installing toothed belt for coolant pump
  255
• 2.8 Removing and installing engine temperature regulation module GX33
  258
• 2.9 Removing and installing coolant temperature sender G62
  261
• 2.10 Removing and installing radiator outlet coolant temperature sender G83
  262
• 2.11 Removing and installing coolant valves
  263
• 3 Coolant pipes
  268
• 3.1 Assembly overview - coolant pipes
  268
• 3.2 Removing and installing coolant pipes
  269
• 4 Radiator, radiator fan
  276
• 4.1 Assembly overview - radiator/radiator fan
  276
• 4.2 Removing and installing radiator module
  279
• 4.3 Dismantling radiator module
  282
• 4.4 Removing and installing radiator cowl
  283
• 4.5 Removing and installing radiator fan
  285
• Turbocharging/supercharging
  286
• 1 Turbocharger
  286
• 1.1 Assembly overview - turbocharger
  286
• 1.2 Removing and installing turbocharger
  290
• 1.3 Removing and installing turbocharger air recirculation valve N249
  296
• 1.4 Removing and installing charge pressure positioner V465
  297
• 2 Charge air system
  299
• 2.1 Assembly overview - charge air system
  299
• 2.2 Assembly overview - charge-air hose connections
  300
• 2.3 Removing and installing charge air cooler
  301
• 2.4 Removing and installing charge pressure sender G31
  303
• 2.5 Checking charge air system for leaks
  304
• Mixture preparation - injection
  307
• 1 Injection system
  307
• 1.1 Overview of fitting locations - injection system
  307
• 1.2 Checking fuel system for leaks
  314
• 2 Injectors
  315
• 2.1 Assembly overview - fuel rail with injectors
  315
• 2.2 Removing and installing fuel rail
  317
• 2.3 Removing and installing injectors
  318
• 2.4 Renewing seals on injectors
  324
• 2.5 Cleaning injectors
  327
• 3 Air filter
  330
• 3.1 Assembly overview - air filter housing
  330
• 3.2 Removing and installing air filter housing
  332
• 4 Intake manifold
  335
• 4.1 Assembly overview - intake manifold
  335
• 4.2 Removing and installing intake manifold
  337
• 4.3 Removing and installing throttle valve module GX3
  341
• 4.4 Cleaning throttle valve module GX3
  342
• 4.5 Checking intake manifold change-over
  343
• 5 Senders and sensors
  346
• 5.1 Removing and installing intake manifold sender GX9
  346
• 5.2 Removing and installing fuel pressure sender G247
  346
• 5.3 Checking fuel pressure sender G247
  348
• 5.4 Removing and installing fuel pressure sender for low-pressure G410
  350
• 6 Engine control unit
  352
• 6.1 Assembly overview - engine control unit
  352
• 6.2 Removing and installing engine control unit J623
  352
• 7 High-pressure pump
  354
• 7.1 Assembly overview - high-pressure pump
  354
• 7.2 Removing and installing high-pressure pump
  356
• 7.3 Removing and installing high-pressure pipe
  359
• 8 Lambda probe
  364
• 8.1 Assembly overview - Lambda probe
  364
• 8.2 Removing and installing Lambda probe
  365
• Exhaust system
  370
• 1 Exhaust pipes and silencers
  370
• 1.1 Assembly overview - silencers
  370
• 1.2 Separating exhaust pipes from silencers
  375
• 1.3 Removing and installing front silencer
  376
• 1.4 Removing and installing silencer
  378
• 1.5 Aligning exhaust system free of stress
  381
• 1.6 Checking exhaust system for leaks
  382
• 2 Emission control
  383
• 2.1 Assembly overview - emission control
  383
• 2.2 Assembly overview – brackets and pipes for pressure differential sender G505
  385
• 2.3 Removing and installing catalytic converter
  386
• 2.4 Removing and installing particulate filter
  389
• 2.5 Removing and installing exhaust flap control unit J883
  390
• 3 Exhaust gas temperature regulation
  391
• 3.1 Removing and installing exhaust gas temperature sender 3 G495
  391
• 3.2 Removing and installing exhaust gas temperature sender 4 G648
  392
• 4 Secondary air system
  394
• 4.1 Assembly overview - secondary air system
  394
• 4.2 Removing and installing secondary air pump motor V101
  396
• 4.3 Removing and installing secondary air inlet valve N112
  397
• 4.4 Removing and installing sender 1 for secondary air pressure G609
  398
• Ignition system
  400
• 1 Ignition system
  400
• 1.1 Assembly overview - ignition system
  400
• 1.2 Removing and installing ignition coils with output stage
  402
• 1.3 Removing and installing knock sensor 1 G61
  405
• 1.4 Removing and installing Hall sender
  406
• 1.5 Removing and installing engine speed sender G28
  407