4-cyl. direct injection engine (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 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 notes
  5
• 3.1 Rules for cleanliness
  5
• 3.2 General information
  5
• 3.3 General repair instructions
  5
• 3.4 Foreign objects in engine
  6
• 3.5 Contact corrosion
  6
• 3.6 Routing and attachment of lines
  6
• 3.7 Fitting radiator and condensers
  6
• 3.8 Checking vacuum system
  6
• Removing and installing engine
  8
• 1 Removing and installing engine
  8
• 1.1 Removing engine
  8
• 1.2 Separating engine and gearbox
  23
• 1.3 Securing engine on engine and gearbox support
  29
• 1.4 Installing engine
  32
• 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
  38
• 2.4 Removing and installing pendulum support
  40
• 2.5 Supporting engine in installation position
  41
• 2.6 Adjusting assembly mountings
  45
• 2.7 Checking adjustment of assembly mountings
  46
• 3 Engine cover panel
  48
• 3.1 Removing and installing engine cover
  48
• Crankshaft group
  49
• 1 Cylinder block (pulley end)
  49
• 1.1 Assembly overview - cylinder block (pulley end)
  49
• 1.2 Removing and installing poly-V belt
  52
• 1.3 Removing and installing tensioner for poly V-belt
  54
• 1.4 Removing and installing vibration damper
  54
• 1.5 Removing and installing bracket for ancillaries
  61
• 1.6 Removing and installing engine support
  64
• 2 Cylinder block, gearbox end
  66
• 2.1 Assembly overview - cylinder block, gearbox end
  66
• 2.2 Removing and installing flywheel
  67
• 2.3 Removing and installing sealing flange on gearbox side
  68
• 3 Crankshaft
  74
• 3.1 Assembly overview - crankshaft
  74
• 3.2 Crankshaft dimensions
  76
• 3.3 Allocation of main bearing shells
  76
• 3.4 Renewing needle bearing in crankshaft
  78
• 3.5 Measuring axial clearance of crankshaft
  81
• 3.6 Measuring radial clearance of crankshaft
  82
• 3.7 Removing and installing sender wheel
  83
• 4 Balancer shaft
  85
• 4.1 Assembly overview - balance shaft
  85
• 4.2 Removing and installing balance shaft
  86
• 5 Pistons and conrods
  93
• 5.1 Assembly overview - pistons and conrods
  93
• 5.2 Removing and installing pistons
  95
• 5.3 Checking pistons and cylinder bores
  96
• 5.4 Separating new conrod
  99
• 5.5 Checking radial clearance of conrods
  100
• Cylinder head, valve gear
  101
• 1 Cylinder head
  101
• 1.1 Assembly overview - cylinder head
  101
• 1.2 Assembly overview - camshaft housing
  104
• 1.3 Removing and installing cylinder head
  106
• 1.4 Removing and installing vacuum pump
  113
• 1.5 Checking compression
  115
• 2 Cover for timing chain
  118
• 2.1 Assembly overview - cover for timing chain
  118
• 2.2 Removing and installing timing chain cover
  121
• 2.3 Renewing seal for vibration damper
  129
• 3 Chain drive
  132
• 3.1 Assembly overview - camshaft timing chains
  132
• 3.2 Assembly overview - drive chain for balance shaft
  136
• 3.3 Removing and installing camshaft timing chain
  139
• 3.4 Removing and installing drive chain for balance shaft
  155
• 3.5 Checking chain elongation
  155
• 3.6 Checking valve timing
  156
• 4 Valve gear
  159
• 4.1 Assembly overview - valve gear
  159
• 4.2 Removing and installing camshaft
  162
• 4.3 Removing and installing camshaft control valve 1 N205
  181
• 4.4 Removing and installing exhaust camshaft control valve 1 N318
  181
• 4.5 Removing and installing valve stem seals
  181
• 5 Inlet and exhaust valves
  192
• 5.1 Checking valve guides
  192
• 5.2 Checking valves
  193
• 5.3 Valve dimensions
  193
• Lubrication
  194
• 1 Sump, oil pump
  194
• 1.1 Assembly overview - sump/oil pump
  194
• 1.2 Engine oil:
  197
• 1.3 Removing and installing lower part of sump
  198
• 1.4 Removing and installing upper part of sump
  202
• 1.5 Removing and installing oil pump
  207
• 1.6 Removing and installing oil level and oil temperature sender G266
  210
• 2 Engine oil cooler
  212
• 2.1 Assembly overview - engine oil cooler
  212
• 2.2 Removing and installing engine oil cooler
  212
• 2.3 Removing and installing mechanical switching valve
  214
• 3 Crankcase ventilation
  215
• 3.1 Assembly overview - crankcase breather system
  215
• 3.2 Removing and installing oil separator
  216
• 4 Oil filter, oil pressure switch
  217
• 4.1 Assembly overview - oil filter
  217
• 4.2 Assembly overview - oil pressure switches/oil pressure control
  217
• 4.3 Removing and installing oil pressure switch F1
  219
• 4.4 Removing and installing oil pressure switch for reduced oil pressure F378
  220
• 4.5 Removing and installing stage 3 oil pressure switch F447
  221
• 4.6 Checking oil pressure
  223
• 4.7 Removing and installing piston cooling jet control valve N522
  227
• 4.8 Removing and installing oil pressure regulating valve N428
  227
• Cooling
  229
• 1 Cooling system/coolant
  229
• 1.1 Connection diagram - coolant hoses
  229
• 1.2 Checking cooling system for leaks
  236
• 1.3 Draining and adding coolant
  239
• 2 Coolant pump, regulation of cooling system
  247
• 2.1 Assembly overview - coolant pump, thermostat
  247
• 2.2 Assembly overview - electric coolant pump
  250
• 2.3 Assembly overview - coolant temperature sender
  253
• 2.4 Removing and installing electric coolant pump
  254
• 2.5 Removing and installing coolant valves
  257
• 2.6 Removing and installing coolant pump
  264
• 2.7 Removing and installing toothed belt for coolant pump
  267
• 2.8 Removing and installing actuator for engine temperature regulation N493
  270
• 2.9 Removing and installing coolant temperature sender G62
  272
• 2.10 Removing and installing radiator outlet coolant temperature sender G83
  273
• 3 Coolant pipes
  275
• 3.1 Assembly overview - coolant pipes
  275
• 3.2 Removing and installing coolant pipes
  275
• 3.3 Removing and installing upper coolant pipes
  277
• 3.4 Removing and installing coolant pipes for gearbox
  278
• 4 Radiator, radiator fan
  281
• 4.1 Assembly overview - radiator, radiator fan
  281
• 4.2 Assembly overview - auxiliary radiator
  283
• 4.3 Assembly overview – radiator cowl and radiator fan
  284
• 4.4 Removing and installing radiator
  285
• 4.5 Removing and installing radiator cowl
  287
• 4.6 Removing and installing radiator fan
  289
• 4.7 Removing and installing auxiliary radiator
  290
• Turbocharging/supercharging
  293
• 1 Turbocharger
  293
• 1.1 Assembly overview - turbocharger
  293
• 1.2 Removing and installing turbocharger
  296
• 1.3 Adjusting charge pressure positioner V465
  302
• 1.4 Removing and installing turbocharger air recirculation valve N249
  304
• 2 Charge air system
  305
• 2.1 Assembly overview - charge air system
  305
• 2.2 Assembly overview - charge-air hose connections
  307
• 2.3 Removing and installing charge air cooler
  307
• 2.4 Removing and installing charge pressure sender G31
  310
• 2.5 Checking charge air system for leaks
  311
• 2.6 Removing and installing air pipe
  313
• Mixture preparation - injection
  316
• 1 Injection system
  316
• 1.1 Overview of fitting locations - injection system
  316
• 1.2 Releasing high pressure in fuel system
  331
• 2 Injectors
  333
• 2.1 Assembly overview - fuel rail with injectors
  333
• 2.2 Removing and installing fuel rail
  335
• 2.3 Removing and installing injectors
  336
• 2.4 Renewing seals on injectors
  344
• 2.5 Cleaning injectors
  347
• 3 Air filter
  349
• 3.1 Assembly overview - air filter housing
  349
• 3.2 Removing and installing air filter housing
  351
• 3.3 Removing and installing air guide on lock carrier
  353
• 4 Intake manifold
  355
• 4.1 Assembly overview – intake manifold
  355
• 4.2 Assembly overview - lower part of intake manifold with fuel rail
  357
• 4.3 Removing and installing intake manifold
  359
• 4.4 Removing and installing throttle valve module GX3
  366
• 4.5 Cleaning throttle valve module
  368
• 4.6 Checking intake manifold change-over
  369
• 5 Senders and sensors
  372
• 5.2 Removing and installing fuel pressure sender G247
  374
• 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
  381
• 6 Engine control unit
  383
• 6.1 Assembly overview – engine/motor control unit
  383
• 6.2 Removing and installing engine control unit J623
  383
• 7 High-pressure pump
  389
• 7.1 Assembly overview - high-pressure pump
  389
• 7.2 Removing and installing high-pressure pump
  391
• 7.3 Removing and installing high-pressure pipe
  396
• 8 Lambda probe
  400
• 8.1 Assembly overview - Lambda probe
  400
• 8.2 Removing and installing Lambda probe
  401
• Exhaust system
  405
• 1 Exhaust pipes and silencers
  405
• 1.1 Assembly overview – silencers
  405
• 1.2 Separating exhaust pipes from silencers
  407
• 1.3 Removing and installing silencer
  410
• 1.4 Aligning exhaust system free of stress
  411
• 1.5 Checking exhaust system for leaks
  412
• 1.6 Installation position of clamp
  413
• 2 Emission control
  415
• 2.1 Assembly overview - emission control
  415
• 2.2 Removing and installing catalytic converter
  420
• 2.3 Removing and installing particulate filter
  426
• Ignition system
  427
• 1 Ignition system
  427
• 1.1 Assembly overview - ignition system
  427
• 1.2 Test data, spark plugs
  429
• 1.3 Removing and installing ignition coils with output stage
  429
• 1.4 Removing and installing knock sensor 1 G61
  431
• 1.5 Removing and installing Hall sender
  432
• 1.6 Removing and installing engine speed sender G28
  433