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

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety precautions when working on exhaust system
  1
• 1.2 Safety regulations for working on fuel supply
  1
• 1.3 Safety measures when working on vehicles with a start/stop system
  2
• 1.5 Safety precautions when working on ignition system
  2
• 1.6 Safety precautions when working on the cooling system
  3
• 2 Identification
  4
• 2.1 Engine number/engine data
  4
• 3 Repair instructions
  6
• 3.1 Rules for cleanliness
  6
• 3.2 General information
  6
• 3.3 General repair instructions
  7
• 3.4 Foreign objects in engine
  8
• 3.5 Contact corrosion
  8
• 3.6 Routing and attachment of lines
  8
• 3.7 Fitting radiator and condensers
  8
• 3.8 Checking vacuum system
  9
• 3.9 Nuts and bolts
  9
• 3.10 Identification labels
  9
• 3.11 Using impact drivers
  10
• 3.12 Checking fuel system for leaks
  10
• Removing and installing engine
  11
• 1 Removing and installing engine
  11
• 1.1 Removing engine
  11
• 1.2 Separating engine and gearbox
  29
• 1.3 Securing engine on engine and gearbox support
  37
• 1.4 Installing engine
  39
• 2 Assembly mountings
  43
• 2.1 Assembly overview – assembly mountings
  43
• 2.2 Removing and installing engine mounting
  45
• 2.3 Removing and installing gearbox mounting
  46
• 2.4 Removing and installing pendulum support
  48
• 2.5 Supporting engine in installation position
  49
• 2.6 Checking adjustment of assembly mountings
  53
• 2.7 Adjusting assembly mountings
  54
• 3 Engine cover panel
  56
• 3.1 Removing and installing engine cover
  56
• Crankshaft group
  57
• 1 Cylinder block (pulley end)
  57
• 1.1 Assembly overview - cylinder block (pulley end)
  57
• 1.2 Removing and installing poly-V belt
  60
• 1.3 Removing and installing tensioner for poly V-belt
  61
• 1.4 Removing and installing vibration damper
  62
• 1.5 Renewing seal for vibration damper
  69
• 1.6 Removing and installing bracket for ancillaries
  72
• 1.7 Removing and installing engine support
  74
• 2 Cylinder block, gearbox end
  77
• 2.1 Assembly overview - cylinder block, gearbox end, flywheel
  77
• 2.2 Assembly overview - cylinder block, gearbox end, drive plate
  78
• 2.3 Removing and installing flywheel
  79
• 2.4 Removing and installing drive plate
  80
• 2.5 Removing and installing sealing flange on gearbox side
  83
• 3 Crankshaft
  88
• 3.1 Assembly overview - crankshaft
  88
• 3.2 Crankshaft dimensions
  91
• 3.3 Allocation of main bearing shells
  91
• 3.4 Renewing needle bearing in crankshaft
  93
• 3.5 Measuring axial clearance of crankshaft
  96
• 3.6 Measuring radial clearance of crankshaft
  97
• 3.7 Removing and installing sender wheel
  98
• 4 Balancer shaft
  100
• 4.1 Assembly overview - balance shaft
  100
• 4.2 Removing and installing balance shaft
  102
• 4.3 Renewing oil seal for balance shaft (inlet side)
  107
• 5 Pistons and conrods
  109
• 5.1 Assembly overview - pistons and conrods
  109
• 5.2 Removing and installing pistons
  114
• 5.3 Checking pistons and cylinder bores
  116
• 5.4 Separating new conrod
  117
• 5.5 Checking radial clearance of conrods
  118
• 5.6 Removing and installing oil spray jets
  118
• Cylinder head, valve gear
  120
• 1 Cylinder head
  120
• 1.1 Assembly overview - cylinder head
  120
• 1.2 Removing and installing cylinder head
  123
• 1.3 Assembly overview - vacuum pump
  130
• 1.4 Removing and installing vacuum pump
  131
• 1.5 Checking compression
  133
• 2 Cover for timing chain
  137
• 2.1 Assembly overview - cover for timing chain
  137
• 2.2 Removing and installing upper timing chain cover
  140
• 2.3 Removing and installing timing chain cover (bottom)
  142
• 3 Chain drive
  147
• 3.1 Assembly overview - camshaft timing chains
  147
• 3.2 Assembly overview - drive chain for balance shaft
  150
• 3.3 Removing and installing camshaft timing chain
  152
• 3.4 Removing and installing drive chain for balance shaft
  165
• 3.5 Removing and installing bearing saddle
  168
• 3.6 Checking valve timing
  174
• 3.7 Checking timing chain
  176
• 4 Valve gear
  178
• 4.1 Assembly overview - valve gear
  178
• 4.2 Removing and installing camshaft
  182
• 4.3 Installing ball for sliding piece
  192
• 4.4 Removing and installing actuators for camshaft adjustment
  193
• 4.5 Removing and installing camshaft control valve 1 N205
  194
• 4.6 Removing and installing exhaust camshaft control valve 1 N318
  195
• 4.7 Removing and installing valve stem oil seals
  195
• 5 Inlet and exhaust valves
  207
• 5.1 Checking valve guides
  207
• 5.2 Checking valves
  208
• 5.3 Valve dimensions
  208
• Lubrication
  209
• 1 Sump, oil pump
  209
• 1.1 Assembly overview - sump/oil pump
  209
• 1.2 Engine oil:
  213
• 1.3 Removing and installing lower part of sump
  213
• 1.4 Removing and installing upper part of sump
  219
• 1.5 Removing and installing oil pump
  224
• 1.6 Removing and installing oil level and oil temperature sender G266
  227
• 2 Engine oil cooler
  229
• 2.1 Assembly overview - engine oil cooler
  229
• 2.2 Removing and installing engine oil cooler
  229
• 2.3 Removing and installing mechanical switching valve
  231
• 3 Crankcase ventilation
  232
• 3.1 Assembly overview - crankcase breather system
  232
• 3.2 Removing and installing oil separator
  233
• 4 Oil filter, oil pressure switch
  235
• 4.1 Assembly overview - oil filter
  235
• 4.2 Assembly overview - oil pressure switches/oil pressure control
  235
• 4.3 Removing and installing piston cooling jet control valve N522
  237
• 4.4 Removing and installing oil pressure switch F1
  238
• 4.5 Removing and installing oil pressure switch for reduced oil pressure F378
  239
• 4.6 Removing and installing stage 3 oil pressure switch F447
  240
• 4.7 Checking oil pressure
  241
• 4.8 Removing and installing oil pressure regulating valve N428
  246
• Cooling
  248
• 1 Cooling system/coolant
  248
• 1.1 Connection diagram - coolant hoses
  248
• 1.2 Assembly overview – coolant expansion tank
  251
• 1.3 Checking cooling system for leaks
  252
• 1.4 Draining and adding coolant
  256
• 1.5 Flushing cooling system
  263
• 1.6 Flushing cooling system, quick reference guide
  286
• 1.7 Removing and installing coolant expansion tank
  287
• 2 Coolant pump, regulation of cooling system
  290
• 2.1 Assembly overview - coolant pump, thermostat
  290
• 2.2 Assembly overview - electric coolant pump
  292
• 2.3 Assembly overview - coolant temperature sender
  294
• 2.4 Removing and installing electric coolant pump
  295
• 2.5 Removing and installing coolant pump
  298
• 2.6 Removing and installing toothed belt for coolant pump
  302
• 2.7 Removing and installing coolant valves
  305
• 2.8 Removing and installing actuator for engine temperature regulation
  308
• 2.9 Removing and installing coolant temperature sender G62
  311
• 2.10 Removing and installing radiator outlet coolant temperature sender G83
  312
• 3 Coolant pipes
  314
• 3.1 Assembly overview - coolant pipes
  314
• 3.2 Removing and installing coolant pipes
  315
• 3.3 Removing and installing upper coolant pipes
  319
• 4 Radiator, radiator fan
  321
• 4.1 Assembly overview – radiator
  321
• 4.2 Assembly overview – radiator cowl and radiator fan
  322
• 4.3 Removing and installing radiator
  323
• 4.4 Removing and installing radiator cowl
  324
• 4.5 Removing and installing radiator fan
  326
• Turbocharging/supercharging
  328
• 1 Turbocharger
  328
• 1.1 Assembly overview - turbocharger
  328
• 1.2 Removing and installing turbocharger
  333
• 1.3 Removing and installing turbocharger air recirculation valve
  345
• 2 Charge air system
  347
• 2.1 Assembly overview - charge air system
  347
• 2.2 Assembly overview - charge-air hose connections
  349
• 2.3 Removing and installing charge air cooler
  349
• 2.4 Removing and installing charge pressure sender G31
  353
• 2.5 Checking charge air system for leaks
  353
• Mixture preparation - injection
  358
• 1 Injection system
  358
• 1.1 Overview of fitting locations - injection system
  358
• 2 Injectors
  370
• 2.1 Assembly overview - fuel rail with injectors
  370
• 2.2 Removing and installing fuel rail
  372
• 2.3 Removing and installing injectors
  373
• 2.4 Renewing seals on injectors
  380
• 2.5 Cleaning injectors
  383
• 3 Air filter
  385
• 3.1 Assembly overview - air filter housing
  385
• 3.2 Removing and installing air filter housing
  387
• 3.3 Removing and installing air guide on lock carrier
  388
• 4 Intake manifold
  390
• 4.1 Assembly overview – intake manifold
  390
• 4.2 Removing and installing intake manifold
  392
• 4.3 Removing and installing throttle valve module GX3
  400
• 4.4 Cleaning throttle valve module
  402
• 4.5 Checking intake manifold change-over
  403
• 5 Senders and sensors
  406
• 5.2 Removing and installing fuel pressure sender G247
  408
• 5.3 Checking fuel pressure sender G247
  410
• 5.4 Removing and installing fuel pressure sender for low-pressure
  414
• 5.5 Removing and installing intake manifold sender GX9
  415
• 5.6 Removing and installing air mass meter G70
  416
• 5.7 Removing and installing exhaust gas pressure sensor 1 G450
  417
• 6 Engine control unit
  419
• 6.1 Assembly overview – engine/motor control unit
  419
• 6.2 Removing and installing engine control unit J623
  419
• 6.3 Removing and installing engine (motor) control unit J623 with protective housing
  421
• 7 High-pressure pump
  425
• 7.1 Assembly overview - high-pressure pump
  425
• 7.2 Removing and installing high-pressure pump
  427
• 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
  442
• 1.3 Aligning exhaust system free of stress
  444
• 1.4 Checking exhaust system for leaks
  445
• 1.5 Installation position of clamp
  445
• 2 Emission control
  447
• 2.1 Assembly overview – emission control
  447
• 2.2 Removing and installing bracket for catalytic converter
  451
• 2.3 Removing and installing catalytic converter
  452
• 2.4 Removing and installing particulate filter
  458
• 3 Exhaust gas temperature regulation
  465
• 3.1 Assembly overview – exhaust gas temperature regulation
  465
• 3.2 Removing and installing parts of exhaust gas temperature regulation
  469
• 4 Secondary air system
  474
• 4.1 Assembly overview - secondary air system
  474
• 4.2 Removing and installing secondary air pump motor V101
  475
• 4.3 Renewing stop buffer for secondary air pump
  476
• 4.4 Removing and installing secondary air inlet valve N112
  477
• Ignition system
  479
• 1 Ignition system
  479
• 1.1 Assembly overview - ignition system
  479
• 1.2 Removing and installing ignition coils with output stage
  481
• 1.3 Removing and installing knock sensor 1 G61
  483
• 1.4 Removing and installing Hall sender
  485
• 1.5 Removing and installing engine speed sender G28
  486