4-cyl. direct injection engine (2.0 l 4V turbocharger, toothed belt drive)

Kapitelübersicht

• Technical data
  1
• 1 Engine number, engine data
  1
• 2 Safety precautions
  2
• 2.1 Safety precautions when working on fuel supply system
  2
• 2.2 Safety precautions when working on ignition system
  2
• 2.3 Releasing pressure in high-pressure area
  3
• 3 General repair notes
  5
• 3.1 Rules for cleanliness
  5
• 3.2 Foreign objects in engine
  5
• Removing and installing engine
  6
• 1 Removing and installing engine
  6
• 1.1 Removing engine
  6
• 1.2 Separating engine and gearbox
  15
• 1.3 Securing engine on engine and gearbox support
  16
• 1.4 Installing engine
  18
• 2 Assembly mountings
  21
• 2.1 Assembly overview - assembly mountings
  21
• 2.2 Removing and installing engine mounting
  22
• 2.3 Removing and installing gearbox mounting
  23
• 2.4 Removing and installing pendulum support
  26
• 2.5 Supporting engine in installation position
  26
• 3 Engine cover panel
  29
• 3.1 Removing and installing engine cover panel
  29
• Crankshaft group
  30
• 1 Cylinder block (pulley end)
  30
• 1.1 Assembly overview - poly V-belt drive
  30
• 1.2 Assembly overview – sealing flange, pulley end
  31
• 1.3 Removing and installing poly V-belt
  32
• 1.4 Removing and installing tensioner for poly V-belt
  34
• 1.5 Removing and installing bracket for ancillaries
  34
• 1.6 Removing and installing vibration damper
  35
• 1.7 Renewing crankshaft oil seal - belt pulley end
  36
• 1.8 Removing and installing sealing flange on pulley end
  38
• 2 Cylinder block, gearbox end
  42
• 2.1 Assembly overview - cylinder block, gearbox end
  42
• 2.2 Removing and installing flywheel
  43
• 2.3 Removing and installing sealing flange on gearbox side
  44
• 3 Crankshaft
  47
• 3.1 Assembly overview - crankshaft
  47
• 3.2 Crankshaft dimensions
  49
• 3.3 Measuring axial clearance of crankshaft
  49
• 3.4 Measuring radial clearance of crankshaft
  50
• 3.5 Removing and installing drive chain sprocket
  51
• 4 Pistons and conrods
  54
• 4.1 Assembly overview - pistons and conrods
  54
• 4.2 Removing and installing pistons
  55
• 4.3 Checking piston and cylinder bore
  57
• 4.4 Checking radial clearance of conrods
  58
• Cylinder head, valve gear
  60
• 1 Cylinder head
  60
• 1.1 Assembly overview - cylinder head
  60
• 1.2 Removing and installing cylinder head
  62
• 1.3 Removing and installing cylinder head cover
  68
• 1.4 Checking compression
  70
• 1.5 Removing and installing vacuum pump
  71
• 2 Toothed belt drive
  73
• 2.1 Assembly overview - toothed belt
  73
• 2.2 Removing and installing toothed belt
  74
• 3 Valve gear
  79
• 3.1 Assembly overview - valve gear
  79
• 3.2 Measuring axial play of camshaft
  81
• 3.3 Measuring radial play of camshaft
  82
• 3.4 Removing and installing camshaft oil seal
  83
• 3.5 Removing and installing camshaft adjuster
  85
• 3.6 Removing and installing inlet camshaft control valve 1 N205
  89
• 3.7 Removing and installing camshaft
  90
• 3.8 Removing and installing valve stem seals
  94
• 4 Inlet and exhaust valves
  103
• 4.1 Checking valve guides
  103
• 4.2 Checking valves
  104
• 4.3 Valve dimensions
  104
• Lubrication
  105
• 1 Sump, oil pump
  105
• 1.1 Assembly overview - sump, oil pump
  105
• 1.2 Engine oil
  106
• 1.3 Removing and installing sump
  106
• 1.4 Removing and installing oil level and oil temperature sender G266
  110
• 2 Engine oil cooler
  111
• 2.1 Removing and installing engine oil cooler
  111
• 3 Oil filter, oil pressure switch
  113
• 3.1 Assembly overview - oil filter housing, oil pressure switch
  113
• 3.2 Draining oil filter housing
  114
• 3.3 Removing and installing oil filter housing
  116
• 3.4 Removing and installing oil pressure switch F1
  116
• 3.5 Checking oil pressure and oil pressure switch
  118
• 4 Balancer shaft module
  120
• 4.1 Assembly overview - balancer shaft module
  120
• 4.2 Removing and installing balance shaft module
  121
• Cooling
  127
• 1 Cooling system, coolant
  127
• 1.1 Coolant hose schematic diagram
  127
• 1.2 Draining and filling coolant
  128
• 1.3 Checking cooling system for leaks
  133
• 2 Coolant pump, regulation of cooling system
  135
• 2.1 Assembly overview - coolant pump, thermostat
  135
• 2.2 Assembly overview - electric coolant pump
  136
• 2.3 Removing and installing continued coolant circulation pump V51
  136
• 2.4 Removing and installing coolant pump
  137
• 2.5 Removing and installing thermostat
  138
• 2.6 Removing and installing coolant temperature sender G62
  139
• 3 Coolant pipes
  142
• 3.1 Assembly overview - coolant pipes
  142
• 3.2 Removing and installing coolant pipes
  143
• 3.3 Removing and installing front right coolant pipe
  145
• 4 Radiator, radiator fan
  147
• 4.1 Assembly overview - radiator, radiator fan
  147
• 4.2 Removing and installing radiator
  148
• 4.3 Removing and installing radiator cowling with radiator fan
  150
• 4.4 Removing and installing radiator fan
  152
• Turbocharging/supercharging
  153
• 1 Turbocharger
  153
• 1.1 Assembly overview - turbocharger
  153
• 1.2 Removing and installing turbocharger
  156
• 1.3 Checking vacuum unit for turbocharger
  161
• 1.4 Renewing vacuum unit for turbocharger
  163
• 1.5 Adjusting vacuum unit for turbocharger
  163
• 2 Charge air system
  168
• 2.1 Schematic overview - charge air system
  168
• 2.2 Assembly overview - charge air system
  169
• 2.3 Assembly overview - charge-air hose connections
  171
• 2.4 Removing and installing charge air cooler
  172
• 2.5 Removing and installing charge pressure sender G31
  173
• 2.6 Checking charge air system for leaks
  173
• Mixture preparation - injection
  176
• 1 Injection system
  176
• 1.1 Overview of fitting locations - injection system
  176
• 2 Air filter
  185
• 2.1 Assembly overview - air filter housing
  185
• 2.2 Removing and installing air filter housing
  186
• 3 Intake manifold
  188
• 3.1 Assembly overview - intake manifold
  188
• 3.2 Assembly overview - intake manifold with fuel rail
  190
• 3.3 Removing and installing intake manifold with fuel rail
  191
• 3.4 Removing and installing throttle valve module J338
  194
• 3.5 Cleaning throttle valve module
  196
• 3.6 Removing and installing intake manifold flap motor V157
  197
• 3.7 Checking intake manifold change-over
  198
• 3.8 Checking double non-return valve
  200
• 4 High-pressure pump
  202
• 4.1 Assembly overview - high-pressure pump
  202
• 4.2 Removing and installing high-pressure pump
  203
• 5 Injectors
  205
• 5.1 Removing and installing fuel rail
  205
• 5.2 Removing and installing injectors
  206
• 5.3 Renewing seals on injectors
  209
• 5.4 Cleaning injectors
  211
• 6 Senders and sensors
  213
• 6.2 Removing and installing air mass meter G70
  214
• 6.3 Removing and installing fuel pressure sender G247
  214
• 6.4 Checking fuel pressure sender G247
  216
• 7 Lambda probe
  219
• 7.1 Assembly overview - Lambda probe
  219
• 7.2 Removing and installing Lambda probe G39
  219
• 7.3 Removing and installing Lambda probe after catalytic converter G130
  221
• 8 Engine control unit
  223
• 8.1 Removing and installing engine control unit J623
  223
• Exhaust system
  225
• 1 Exhaust pipes, silencers
  225
• 1.1 Assembly overview - silencers
  225
• 1.2 Separating exhaust pipes, silencers
  226
• 1.3 Aligning exhaust system free of stress
  227
• 1.4 Checking exhaust system for leaks
  228
• 2 Emission control
  229
• 2.1 Assembly overview - emission control
  229
• 2.2 Removing and installing catalytic converter
  230
• 3 Exhaust manifold
  233
• Ignition system
  234
• 1 Ignition system
  234
• 1.1 Assembly overview - ignition system
  234
• 1.2 Test data, spark plugs
  235
• 1.3 Removing and installing ignition coils with output stage
  236
• 1.4 Removing and installing knock sensor 1 G61
  237
• 1.5 Removing and installing knock sensor 2 G66
  238
• 1.6 Removing and installing Hall sender G40
  239
• 1.7 Removing and installing engine speed sender G28
  239