4-cylinder injection engine (hybrid vehicles)

Kapitelübersicht

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety precautions when working on a high-voltage system
  1
• 1.2 Safety precautions when working in the vicinity of high-voltage components
  2
• 1.3 Safety regulations for working on fuel supply
  2
• 1.5 Safety precautions when working on ignition system
  3
• 1.6 Safety precautions when working on the cooling system
  3
• 2 Identification
  4
• 2.1 Engine number/engine data
  4
• 3 Repair notes
  6
• 3.1 Rules for cleanliness
  6
• 3.2 Foreign objects in engine
  6
• 3.3 Contact corrosion
  6
• 3.4 Pipe/wire routing and attachment
  7
• 3.5 Fitting radiator and condensers
  7
• 3.6 Checking vacuum system
  7
• 4 Classification of dangers of the high-voltage system
  8
• Removing and installing engine
  15
• 1 Removing and installing engine
  15
• 1.1 Removing engine
  15
• 1.2 Separating engine and gearbox
  25
• 1.3 Securing engine on engine and gearbox support
  27
• 1.4 Installing engine
  29
• 2 Assembly mounting
  34
• 2.1 Assembly overview - assembly mountings
  34
• 2.2 Supporting engine in installation position
  35
• 2.3 Removing and installing motor mounting
  39
• 2.4 Removing and installing gearbox mounting
  43
• 2.5 Removing and installing pendulum support
  43
• 2.6 Checking adjustment of assembly mountings (engine and gearbox mountings)
  44
• 2.7 Adjusting assembly mountings
  45
• 3 Motor cover
  47
• 3.1 Removing and installing engine cover
  47
• Crankshaft group
  48
• 1 Cylinder block (pulley end)
  48
• 1.1 Assembly overview - sealing flange, vibration damper
  48
• 1.2 Removing and installing engine support
  49
• 1.3 Removing and installing vibration damper
  50
• 1.4 Renewing crankshaft oil seal - belt pulley end
  51
• 1.5 Removing and installing sealing flange on pulley end
  53
• 2 Cylinder block, gearbox end
  56
• 2.1 Assembly overview - cylinder block, gearbox end
  56
• 2.2 Removing and installing flywheel
  57
• 2.3 Removing and installing sealing flange on gearbox side
  58
• 3 Camshaft
  68
• 3.1 Crankshaft dimensions
  68
• 3.2 Measuring axial clearance of crankshaft
  68
• 3.3 Renewing needle bearing in crankshaft
  69
• 4 Pistons and conrods
  72
• 4.1 Assembly overview - pistons and conrods
  72
• 4.2 Removing and installing pistons
  74
• 4.3 Removing and installing oil spray jets
  75
• 4.4 Checking pistons and cylinder bores
  76
• 4.5 Checking radial clearance of conrods
  77
• Cylinder head, valve gear
  79
• 1 Cylinder head
  79
• 1.1 Assembly overview - cylinder head
  79
• 1.2 Assembly overview - camshaft housing
  81
• 1.3 Removing and installing cylinder head
  82
• 1.4 Removing and installing camshaft housing
  86
• 1.5 Checking compression
  95
• 2 Toothed belt drive
  97
• 2.1 Assembly overview - toothed belt cover
  97
• 2.2 Assembly overview - toothed belt
  98
• 2.3 Removing toothed belt from camshaft
  100
• 2.4 Removing and installing toothed belt
  112
• 3 Valve gear
  127
• 3.1 Assembly overview - valve gear
  127
• 3.2 Removing and installing inlet camshaft control valve 1 N205
  128
• 3.3 Measuring axial play of camshaft
  128
• 3.4 Removing and installing camshaft oil seal
  129
• 3.5 Removing and installing valve stem seals
  134
• 4 Inlet and exhaust valves
  142
• 4.1 Checking valve guides
  142
• 4.2 Checking valves
  142
• 4.3 Valve dimensions
  143
• Lubrication
  144
• 1 Sump, oil pump
  144
• 1.1 Assembly overview - sump/oil pump
  144
• 1.2 Engine oil:
  148
• 1.3 Removing and installing lower part of sump
  149
• 1.4 Removing and installing upper part of sump
  153
• 1.5 Removing and installing oil pump
  156
• 1.6 Removing and installing oil level and oil temperature sender G266
  157
• 2 Engine oil cooler
  159
• 2.1 Assembly overview - engine oil cooler
  159
• 2.2 Removing and installing engine oil cooler
  159
• 3 Crankcase ventilation
  161
• 3.1 Assembly overview - crankcase breather system
  161
• 3.2 Removing and installing oil separator
  162
• 4 Oil filter, oil pressure switch
  164
• 4.1 Assembly overview - oil filter/oil pressure switch
  164
• 4.2 Removing and installing oil pressure switch F22
  165
• 4.3 Removing and installing oil pressure switch for reduced oil pressure F378
  166
• 4.4 Removing and installing oil pressure regulating valve N428
  168
• 4.5 Checking oil pressure
  169
• Cooling
  171
• 1 Cooling system/coolant
  171
• 1.1 Connection diagram - coolant hoses
  171
• 1.2 Coolant hose schematic diagram, high-voltage system
  173
• 1.3 Checking cooling system for leaks
  174
• 1.4 Checking cooling system of high-voltage system for leaks
  176
• 1.5 Draining and adding coolant
  185
• 1.6 Draining and adding coolant, high-voltage system
  191
• 1.7 Checking filling quality of cooling system, high-voltage system
  198
• 2 Coolant pump, regulation of cooling system
  201
• 2.1 Assembly overview - coolant pump, thermostat
  201
• 2.2 Assembly overview - electric coolant pump
  204
• 2.3 Assembly overview - coolant temperature sender
  205
• 2.4 Removing and installing electric coolant pump
  205
• 2.5 Removing and installing coolant pump
  211
• 2.6 Removing and installing thermostat
  214
• 2.7 Removing and installing toothed belt pulley for coolant pump
  218
• 2.8 Removing and installing coolant temperature sender G62
  219
• 2.9 Removing and installing radiator outlet coolant temperature sender G83
  220
• 2.10 Removing and installing coolant valves
  221
• 2.11 Removing and installing coolant temperature sender for heater G241
  227
• 2.12 Removing and installing engine temperature sender 2 G652
  228
• 2.13 Overview of fitting locations - electric coolant pumps
  229
• 2.14 Assembly overview - coolant valves
  231
• 3 Coolant pipes
  232
• 3.1 Assembly overview - coolant pipes
  232
• 3.2 Removing and installing coolant pipes
  232
• 4 Radiator, radiator fan
  238
• 4.1 Assembly overview - radiator, radiator fan
  238
• 4.2 Assembly overview - radiator cowl and radiator fan
  240
• 4.3 Removing and installing radiator
  240
• 4.4 Removing and installing radiator cowling
  244
• 4.5 Removing and installing radiator fan V7
  245
• Turbocharging/supercharging
  247
• 1 Exhaust turbocharger
  247
• 1.1 Assembly overview - turbocharger
  247
• 1.2 Removing and installing turbocharger
  248
• 1.3 Removing and installing charge pressure positioner V465
  255
• 2 Charge air system
  256
• 2.1 Assembly overview - charge air system
  256
• 2.2 Assembly overview - charge-air hose connections
  257
• 2.3 Removing and installing charge pressure sender GX26
  258
• 2.4 Removing and installing charge air cooler
  258
• 2.5 Checking charge air system for leaks
  259
• Mixture preparation - injection
  261
• 1 Injection system
  261
• 1.1 Overview of fitting locations - injection system
  261
• 1.2 Releasing high pressure in fuel system
  266
• 2 Injectors
  268
• 2.1 Assembly overview - fuel rail with injectors
  268
• 2.2 Removing and installing fuel rail
  269
• 2.3 Removing and installing injectors
  269
• 2.4 Cleaning injectors
  275
• 3 Air filter
  276
• 3.1 Assembly overview - air filter housing
  276
• 3.2 Removing and installing air filter housing
  277
• 4 Intake manifold
  278
• 4.1 Assembly overview - intake manifold
  278
• 4.2 Removing and installing intake manifold
  279
• 4.3 Removing and installing throttle valve module GX3
  282
• 4.4 Cleaning throttle valve module GX3
  284
• 5 Senders and sensors
  286
• 5.1 Removing and installing intake manifold sender GX9
  286
• 5.2 Removing and installing fuel pressure sender G247
  286
• 5.3 Checking fuel pressure sender G247
  287
• 6 Engine (motor) control unit
  290
• 6.1 Removing and installing engine (motor) control unit J623
  290
• 7 High-pressure pump
  294
• 7.1 Assembly overview - high-pressure pump
  294
• 7.2 Removing and installing high-pressure pump
  295
• 7.3 Removing and installing high-pressure pipe
  296
• 8 Lambda probe
  298
• 8.1 Assembly overview - Lambda probe
  298
• Exhaust system
  301
• 1 Exhaust pipes, silencers
  301
• 1.1 Assembly overview - silencers
  301
• 1.2 Removing and installing silencer
  301
• 1.3 Aligning exhaust system free of stress
  302
• 1.4 Check exhaust system for leaks
  302
• 2 Exhaust gas cleaning
  303
• 2.1 Assembly overview - emission control
  303
• 2.2 Removing and installing catalytic converter
  304
• Ignition system
  308
• 1 Ignition system
  308
• 1.1 Assembly overview - ignition system
  308
• 1.2 Test data, spark plugs
  309
• 1.3 Removing and installing ignition coils with output stage
  309
• 1.4 Removing and installing knock sensor 1 G61
  311
• 1.5 Removing and installing Hall sender G40
  312
• 1.6 Removing and installing engine speed sender G28
  314
• Electric drive systems
  316
• 1 Warning stickers
  316
• 1.1 Checking warning stickers
  316
• 2 High-voltage components
  321
• 2.1 Overview of fitting locations - high-voltage components
  321
• 2.2 Testing high-voltage components and high-voltage cables
  322
• 3 High-voltage battery unit
  323
• 3.1 Assembly overview - high-voltage battery
  323
• 3.2 Visual inspection of high-voltage battery 1 AX2
  324
• 3.3 Removing and installing high-voltage battery 1 AX2
  324
• 3.4 Raising high-voltage battery 1 AX2
  330
• 3.5 Removing and installing battery regulation control unit J840
  331
• 4 Power and control electronics for electric drive
  333
• 4.1 Assembly overview - power and control electronics for electric drive
  333
• 4.3 Removing and installing power and control electronics for electric drive
  336
• 4.4 Removing and installing bracket for power and control electronics for electric drive JX1
  340
• 4.5 Removing and installing high-voltage system fuse 3 S353
  341
• 5 Charging unit for high-voltage battery
  344
• 5.1 Assembly overview - charging unit for high-voltage battery
  344
• 5.2 Removing and installing charging unit 1 for high-voltage battery AX4
  345
• 6 Electric drive motor
  349
• 6.1 Removing and installing three-phase current drive VX54
  349
• 6.2 Removing and installing drive motor temperature sender G712
  349
• 6.3 Removing and installing drive motor rotor position sender 1 G713
  349
• 7 High-voltage cables
  350
• 7.1 Overview of fitting locations - high-voltage cables
  350
• 7.2 Removing and installing high-voltage wiring harness for high-voltage battery
  353
• 7.3 Removing and installing high-voltage wiring harness for drive motor
  357
• 7.5 Removing and installing high-voltage cable for high-voltage heater (PTC)
  361
• 8 Charging socket
  364
• 8.1 Assembly overview - charging socket
  364
• 8.2 Removing and installing high-voltage battery charging socket 1 UX4
  365
• 8.3 Emergency release charging connector
  366
• 8.4 Removing and installing button and display module
  368
• 9 De-energising high-voltage system
  369
• 10 Re-energising high-voltage system
  371
• 11 Potential equalisation lines
  372
• 11.1 General notes - potential equalisation lines
  372
• 11.2 Overview of fitting locations - potential equalisation lines
  372
• 11.3 Removing and installing potential equalisation line for high-voltage battery 1 AX2
  375