4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation II)

Kapitelübersicht

• 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
• 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 engine
  7
• 1.1 Removing engine
  7
• 1.2 Separating engine and gearbox
  19
• 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 Supporting engine in installation position
  27
• 2.3 Removing and installing engine mounting
  31
• 2.4 Removing and installing gearbox mounting
  32
• 2.5 Removing and installing pendulum support
  34
• 2.6 Checking adjustment of assembly mountings
  35
• 2.7 Adjusting assembly mountings
  35
• 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
  43
• 1.4 Removing and installing bracket for ancillaries
  46
• 1.5 Removing and installing vibration damper
  48
• 1.6 Removing and installing engine support
  56
• 2 Cylinder block, gearbox end
  58
• 2.1 Assembly overview - cylinder block, gearbox end
  58
• 2.2 Removing and installing flywheel
  59
• 2.3 Removing and installing sealing flange on gearbox side
  61
• 3 Crankshaft
  70
• 3.1 Assembly overview - crankshaft
  70
• 3.2 Crankshaft dimensions
  72
• 3.3 Allocation of main bearing shells
  72
• 3.4 Renewing needle bearing in crankshaft
  74
• 3.5 Measuring axial clearance of crankshaft
  76
• 3.6 Measuring radial clearance of crankshaft
  77
• 3.7 Removing and installing sender wheel
  78
• 4 Balancer shaft
  80
• 4.1 Assembly overview - balance shaft
  80
• 4.2 Removing and installing balance shaft
  83
• 5 Pistons and conrods
  91
• 5.1 Assembly overview - pistons and conrods
  91
• 5.2 Removing and installing pistons
  95
• 5.3 Removing and installing oil spray jets
  97
• 5.4 Checking pistons and cylinder bores
  98
• 5.5 Separating new conrod
  101
• 5.6 Checking radial clearance of conrods
  101
• Cylinder head, valve gear
  103
• 1 Cylinder head
  103
• 1.1 Assembly overview - cylinder head
  103
• 1.2 Renewing oil non-return valve in cylinder head
  107
• 1.3 Removing and installing cylinder head
  108
• 1.4 Checking compression
  125
• 1.5 Removing and installing vacuum pump
  127
• 2 Cover for timing chain
  129
• 2.1 Assembly overview - cover for timing chain
  129
• 2.2 Removing and installing upper timing chain cover
  131
• 2.3 Removing and installing timing chain cover (bottom)
  134
• 2.4 Renewing seal for vibration damper
  139
• 3 Chain drive
  143
• 3.1 Assembly overview - camshaft timing chains
  143
• 3.2 Removing and installing camshaft timing chain
  144
• 3.3 Removing and installing drive chain for balance shaft
  161
• 3.4 Checking valve timing
  162
• 4 Valve gear
  165
• 4.1 Assembly overview - valve gear
  165
• 4.2 Removing and installing camshaft
  168
• 4.3 Removing and installing camshaft control valve 1 N205
  187
• 4.4 Measuring axial play of camshaft
  187
• 4.5 Renewing valve stem seals
  188
• 5 Inlet and exhaust valves
  201
• 5.1 Checking valve guides
  201
• Lubrication
  203
• 1 Sump, oil pump
  203
• 1.1 Assembly overview - sump/oil pump
  203
• 1.2 Removing and installing lower part of sump
  206
• 1.3 Removing and installing oil pump
  209
• 1.4 Removing and installing upper part of sump
  211
• 1.5 Engine oil:
  216
• 2 Engine oil cooler
  218
• 2.1 Removing and installing engine oil cooler
  218
• 3 Crankcase ventilation
  220
• 3.1 Removing and installing oil separator
  220
• 4 Oil filter, oil pressure switch
  221
• 4.1 Assembly overview - oil filter/oil pressure switch
  221
• 4.2 Removing and installing oil pressure regulating valve N428
  223
• 4.3 Removing and installing oil pressure switch F1
  223
• 4.4 Removing and installing oil pressure switch for reduced oil pressure F378
  225
• 4.5 Checking oil pressure
  226
• Cooling
  230
• 1 Cooling system/coolant
  230
• 1.1 Connection diagram - coolant hoses
  230
• 1.2 Draining and adding coolant
  231
• 1.3 Checking cooling system for leaks
  237
• 2 Coolant pump, regulation of cooling system
  242
• 2.1 Assembly overview - coolant pump, thermostat
  242
• 2.2 Assembly overview - electric coolant pump
  245
• 2.3 Removing and installing electric coolant pump
  246
• 2.4 Removing and installing coolant pump with thermostat housing
  248
• 2.5 Removing and installing coolant pump on thermostat housing
  250
• 2.6 Removing and installing thermostat
  253
• 2.7 Removing and installing toothed belt for coolant pump
  256
• 2.8 Renewing oil seal for coolant pump drive
  259
• 2.9 Removing and installing coolant temperature sender G62
  261
• 3 Coolant pipes
  264
• 3.1 Assembly overview - coolant pipes
  264
• 3.2 Removing and installing lower coolant pipes
  264
• 3.3 Removing and installing upper coolant pipes
  266
• 4 Radiator, radiator fan
  270
• 4.1 Assembly overview - radiator/radiator fan
  270
• 4.2 Removing and installing radiator
  270
• 4.3 Removing and installing radiator cowl
  271
• 4.4 Removing and installing radiator fan V7 and radiator fan 2 V177
  273
• Turbocharging/supercharging
  275
• 1 Turbocharger
  275
• 1.1 Assembly overview - turbocharger
  275
• 1.2 Removing and installing turbocharger
  280
• 1.3 Checking vacuum unit for turbocharger
  287
• 1.4 Renewing vacuum unit for turbocharger
  289
• 2 Charge air system
  290
• 2.1 Schematic overview - charge air system
  290
• 2.2 Assembly overview - charge air system
  291
• 2.3 Assembly overview - charge-air hose connections
  292
• 2.4 Removing and installing charge air cooler
  293
• 2.5 Checking charge air system for leaks
  295
• Mixture preparation - injection
  299
• 1 Injection system
  299
• 1.1 Overview of fitting locations - injection system
  299
• 2 Injectors
  306
• 2.1 Assembly overview - fuel rail with injectors
  306
• 2.2 Removing and installing injectors
  308
• 2.3 Renewing seals on injectors
  312
• 2.4 Cleaning injectors
  314
• 3 Air filter
  317
• 3.1 Assembly overview - air filter housing
  317
• 3.2 Removing and installing air filter housing
  319
• 4 Intake manifold
  320
• 4.1 Assembly overview – intake manifold
  320
• 4.2 Removing and installing intake manifold with fuel rail
  322
• 4.3 Removing and installing fuel rail
  329
• 4.4 Removing and installing throttle valve module J338
  330
• 4.5 Cleaning throttle valve module
  332
• 4.6 Checking intake manifold change-over
  333
• 5 Senders and sensors
  336
• 5.2 Removing and installing air mass meter G70
  336
• 5.3 Removing and installing fuel pressure sender G247
  337
• 5.4 Checking fuel pressure sender G247
  339
• 6 Engine (motor) control unit
  344
• 6.1 Removing and installing engine control unit J623
  344
• 7 High-pressure pump
  350
• 7.1 Assembly overview - high-pressure pump
  350
• 7.2 Removing and installing high-pressure pump
  352
• Exhaust system
  355
• 1 Exhaust pipes and silencers
  355
• 1.1 Assembly overview – silencers
  355
• 1.2 Separating exhaust pipes from silencers
  357
• 1.3 Aligning exhaust system free of stress
  359
• 1.4 Installation position of clamp
  360
• 1.5 Checking exhaust system for leaks
  361
• 2 Emission control
  362
• 2.1 Assembly overview – emission control
  362
• 2.2 Removing and installing catalytic converter
  364
• 3 Exhaust manifold
  367
• Ignition system
  368
• 1 Ignition system
  368
• 1.1 Assembly overview - ignition system
  368
• 1.2 Removing and installing ignition coils with output stage
  369
• 1.3 Removing and installing knock sensor 1 G61
  370
• 1.4 Removing and installing engine speed sender G28
  371
• 1.5 Test data, spark plugs
  372