4-cyl. injection engine (2.0 l engine, EA 888, chain drive)

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety regulations for working on fuel supply
  1
• 1.3 Safety precautions when working on the cooling system
  2
• 1.4 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 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
• 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
  18
• 1.4 Installing engine
  19
• 2 Assembly mountings
  22
• 2.1 Assembly overview - assembly mountings
  22
• 2.2 Removing and installing engine mounting
  24
• 2.3 Supporting engine in installation position
  28
• 2.4 Adjusting assembly mountings
  32
• 2.5 Checking adjustment of assembly mountings (engine and gearbox mountings)
  34
• 3 Engine cover panel
  35
• 3.1 Removing and installing engine cover
  35
• Crankshaft group
  36
• 1 Cylinder block (pulley end)
  36
• 1.1 Assembly overview - poly V-belt drive
  36
• 1.2 Removing and installing poly-V belt
  38
• 1.3 Removing and installing tensioner for poly V-belt
  39
• 1.4 Removing and installing vibration damper
  43
• 1.5 Renewing seal for vibration damper
  44
• 1.6 Removing and installing bracket for ancillaries
  46
• 2 Cylinder block, gearbox end
  49
• 2.1 Assembly overview - cylinder block, gearbox end
  49
• 2.2 Removing and installing flywheel
  50
• 2.3 Removing and installing sealing flange on gearbox side
  52
• 3 Crankshaft
  58
• 3.1 Assembly overview - crankshaft
  58
• 3.2 Crankshaft dimensions
  59
• 3.3 Allocation of main bearing shells
  60
• 3.4 Renewing needle bearing in crankshaft
  61
• 3.5 Measuring axial clearance of crankshaft
  63
• 3.6 Measuring radial clearance of crankshaft
  64
• 3.7 Removing and installing sender wheel
  65
• 4 Pistons and conrods
  66
• 4.1 Assembly overview - pistons and conrods
  66
• 4.2 Checking pistons and cylinder bores
  67
• 4.3 Separating new conrod
  70
• Cylinder head, valve gear
  71
• 1 Cylinder head
  71
• 1.1 Assembly overview - cylinder head
  71
• 1.2 Removing and installing cylinder head
  75
• 1.3 Removing and installing vacuum pump
  91
• 1.4 Checking compression
  92
• 2 Cover for timing chain
  95
• 2.1 Assembly overview - cover for timing chain
  95
• 2.2 Removing and installing upper timing chain cover
  96
• 2.3 Removing and installing timing chain cover (bottom)
  98
• 3 Chain drive
  106
• 3.1 Assembly overview - camshaft timing chains
  106
• 3.2 Assembly overview - drive chain for balance shaft
  107
• 3.3 Removing and installing camshaft timing chain
  109
• 3.4 Removing and installing drive chain for balance shaft
  121
• 3.5 Removing and installing balance shaft for inlet camshaft
  124
• 3.6 Removing and installing balance shaft for exhaust camshaft
  127
• 3.7 Checking valve timing
  130
• 4 Valve gear
  132
• 4.1 Assembly overview - valve gear
  132
• 4.2 Measuring axial play of camshaft
  133
• 4.3 Removing and installing camshaft
  134
• 4.4 Removing and installing camshaft control valve 1 N205
  142
• 4.5 Removing and installing valve stem seals
  143
• 5 Inlet and exhaust valves
  148
• 5.1 Checking valve guides
  148
• 5.2 Valve dimensions
  149
• Lubrication
  150
• 1 Sump, oil pump
  150
• 1.1 Assembly overview - sump/oil pump
  150
• 1.2 Engine oil:
  153
• 1.3 Removing and installing lower part of sump
  154
• 1.4 Removing and installing upper part of sump
  156
• 1.5 Removing and installing oil pump
  161
• 2 Crankcase ventilation
  164
• 2.1 Removing and installing oil separator
  164
• 3 Oil filter, oil pressure switch
  165
• 3.1 Assembly overview - oil filter housing, oil pressure switch F1
  165
• 3.3 Removing and installing engine oil cooler
  167
• 3.4 Checking oil pressure and oil pressure switch F1
  168
• 3.5 Checking oil pressure and oil pressure switch for reduced oil pressure F378
  171
• 3.6 Removing and installing oil pressure switch F22
  175
• 3.7 Removing and installing oil pressure switch for reduced oil pressure F378
  176
• 3.8 Removing and installing oil pressure regulating valve N428
  177
• Cooling
  179
• 1 Cooling system/coolant
  179
• 1.1 Connection diagram - coolant hoses
  179
• 1.2 Checking cooling system for leaks
  181
• 1.3 Draining and adding coolant
  183
• 2 Coolant pump, regulation of cooling system
  189
• 2.1 Assembly overview - coolant pump, thermostat
  189
• 2.2 Assembly overview - electric coolant pump
  191
• 2.3 Removing and installing electric coolant pump
  191
• 2.4 Removing and installing coolant pump
  192
• 2.5 Removing and installing thermostat
  193
• 2.6 Removing and installing toothed belt for coolant pump
  196
• 2.7 Renewing seal for coolant pump drive
  199
• 2.8 Removing and installing coolant temperature sender G62
  200
• 3 Coolant pipes
  204
• 3.1 Assembly overview - coolant pipes
  204
• 3.2 Removing and installing front coolant pipes
  205
• 3.3 Removing and installing small coolant pipe
  208
• 4 Radiator, radiator fan
  210
• 4.1 Assembly overview - radiator/radiator fan
  210
• 4.2 Removing and installing radiator
  211
• 4.3 Removing and installing radiator cowl with radiator fan
  212
• 4.4 Removing and installing radiator fan V7 and radiator fan 2 V177
  214
• Turbocharging/supercharging
  215
• 1 Exhaust turbocharger
  215
• 1.1 Assembly overview - turbocharger
  215
• 1.2 Removing and installing turbocharger
  221
• 1.3 Checking vacuum unit for turbocharger
  227
• 1.4 Renewing vacuum unit for turbocharger
  229
• 2 Charge air system
  231
• 2.1 Schematic overview - charge air system
  231
• 2.2 Assembly overview - charge air system
  232
• 2.3 Removing and installing charge air cooler
  233
• 2.4 Checking charge air system for leaks
  235
• Mixture preparation - injection
  239
• 1 Injection system
  239
• 1.1 Overview of fitting locations - injection system
  239
• 1.2 Releasing high pressure in fuel system
  245
• 2 Injectors
  246
• 2.1 Removing and installing injectors
  246
• 2.2 Renewing seals on injectors
  249
• 2.3 Cleaning injectors
  251
• 3 Air filter
  253
• 3.1 Assembly overview - air filter housing
  253
• 3.2 Removing and installing air filter housing
  254
• 3.3 Removing and installing air filter element
  256
• 4 Intake manifold
  259
• 4.1 Assembly overview - intake manifold
  259
• 4.2 Removing and installing intake manifold with fuel rail
  261
• 4.3 Removing and installing throttle valve module J338
  268
• 4.4 Cleaning throttle valve module J338
  270
• 4.5 Checking intake manifold change-over
  270
• 5 Senders and sensors
  273
• 5.1 Removing and installing fuel pressure sender G247
  273
• 5.2 Checking fuel pressure sender G247
  275
• 5.3 Removing and installing air mass meter
  277
• 6 Engine (motor) control unit
  279
• 6.1 Removing and installing engine (motor) control unit J623
  279
• 7 High-pressure pump
  281
• 7.1 Assembly overview - high-pressure pump
  281
• 7.2 Assembly overview - fuel rail with injectors
  282
• 7.3 Removing and installing high-pressure pump
  284
• Exhaust system
  288
• 1 Exhaust pipes and silencers
  288
• 1.1 Assembly overview - silencers
  288
• 1.2 Removing and installing front exhaust pipe
  290
• 1.3 Separating exhaust pipes from silencers
  292
• 1.4 Aligning exhaust system free of stress
  294
• 1.5 Check exhaust system for leaks
  296
• 2 Secondary air system
  297
• 2.1 Assembly overview - secondary air system
  297
• 2.2 Removing and installing secondary air pump motor V101
  297
• 2.3 Removing and installing secondary air inlet valve N112
  298
• Ignition system
  300
• 1 Ignition system
  300
• 1.1 Assembly overview - ignition system
  300
• 1.2 Test data, spark plugs
  301
• 1.3 Removing and installing ignition coils with output stage
  302
• 1.4 Removing and installing knock sensor 1 G61
  303
• 1.5 Removing and installing engine speed sender G28
  304