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

Chapter overview

• 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
  7
• 1.2 Securing engine to assembly stand
  12
• 1.3 Installing engine
  14
• 3 Engine cover
  18
• Crankshaft group
  19
• 1 Cylinder block (pulley end)
  19
• 1.1 Assembly overview - cylinder block, belt pulley end
  19
• 1.2 Assembly overview - poly V-belt drive
  22
• 1.3 Removing and installing poly V-belt
  23
• 1.4 Removing and installing tensioning element for poly V-belt
  24
• 1.5 Removing and installing bracket for ancillaries
  24
• 1.6 Renewing crankshaft oil seal - belt pulley end
  26
• 1.7 Removing and installing sealing flange on pulley end
  28
• 2 Cylinder block, gearbox end
  32
• 2.1 Assembly overview - cylinder block, gearbox end
  32
• 2.2 Removing and installing sealing flange on gearbox side
  34
• 2.3 Removing and installing flywheel
  35
• 2.4 Removing and installing drive plate
  36
• 3 Crankshaft
  38
• 3.1 Assembly overview - crankshaft
  38
• 3.2 Renewing needle bearing in crankshaft
  40
• 3.3 Crankshaft dimensions
  41
• 3.4 Allocation of main bearings
  41
• 4 Pistons and conrods
  43
• 4.1 Assembly overview - pistons and conrods
  43
• 4.2 Separating new conrod
  44
• 4.3 Removing and installing pistons
  45
• 4.4 Checking piston and cylinder bore
  46
• Cylinder head, valve gear
  49
• 1 Cylinder head
  49
• 1.1 Assembly overview - cylinder head
  49
• 1.2 Removing and installing cylinder head cover
  51
• 1.3 Removing and installing cylinder head
  53
• 1.4 Checking compression
  58
• 2 Toothed belt drive
  60
• 2.1 Removing and installing toothed belt
  60
• 3 Valve gear
  70
• 3.1 Assembly overview - valve gear
  70
• 3.2 Removing and installing valve stem seals
  72
• 3.3 Removing and installing camshaft adjuster
  77
• 3.4 Removing and installing inlet camshaft control valve 1 N205
  80
• 3.5 Removing and installing camshaft oil seal
  82
• 3.6 Removing and installing camshafts
  85
• 3.7 Inlet and exhaust valves
  88
• Lubrication
  90
• 1 Sump, oil pump
  90
• 1.1 Engine oil
  90
• 1.2 Assembly overview - sump
  90
• 1.3 Removing and installing oil level and oil temperature sender G266
  92
• 1.4 Removing and installing sump
  92
• 2 Oil filter, oil pressure switch
  96
• 2.1 Assembly overview - oil filter housing, oil pressure switch
  96
• 2.2 Removing and installing oil filter housing
  98
• 2.3 Checking oil pressure and oil pressure switch
  99
• 2.4 Removing and installing oil pressure switch F1
  100
• 3 Balancer shaft module
  102
• 3.1 Assembly overview - balancer shaft module
  102
• 3.2 Removing and installing balance shaft module
  103
• Cooling
  108
• 1 Cooling system, coolant
  108
• 1.1 Coolant hose schematic diagram
  108
• 1.2 Draining and filling coolant
  110
• 1.3 Checking cooling system for leaks
  114
• 2 Coolant pump, regulation of cooling system
  117
• 2.1 Assembly overview - coolant pump, thermostat
  117
• 2.2 Removing and installing coolant pump
  119
• 2.3 Removing and installing thermostat
  120
• 2.4 Removing and installing coolant temperature sender
  121
• 2.5 Electric coolant pump
  122
• 3 Coolant pipes
  125
• 3.1 Assembly overview - coolant pipes
  125
• 3.2 Removing and installing coolant pipes
  126
• 4 Coolers, radiator, radiator fan
  129
• 4.1 Assembly overview - radiator, radiator fan
  129
• 4.3 Removing and installing radiator
  131
• Turbocharging/supercharging
  133
• 1 Turbocharger
  133
• 1.1 Assembly overview - turbocharger
  133
• 1.2 Removing and installing turbocharger
  138
• 1.3 Checking vacuum unit for turbocharger
  146
• 2 Charge air system
  148
• 2.1 Fitting hose connections with plug-in connectors
  148
• 2.2 Assembly overview - charge air system
  149
• 2.3 Schematic overview - charge air system
  151
• 2.4 Removing and installing charge air cooler
  151
• 2.5 Removing and installing charge pressure sender G31
  153
• 2.6 Checking charge air system for leaks
  153
• Mixture preparation - injection
  156
• 1 Injection system
  156
• 1.1 Vacuum system
  156
• 1.2 Overview of fitting locations
  157
• 2 Injectors
  159
• 2.1 Removing and installing injectors
  159
• 2.2 Renewing seals on injectors
  161
• 2.3 Cleaning injectors
  163
• 3 High-pressure pump
  165
• 3.1 Assembly overview - high-pressure pump
  165
• 3.2 Removing and installing high-pressure pump
  166
• 3.3 Assembly overview - fuel pipes and fuel rail
  167
• 4 Senders and sensors
  170
• 4.1 Actuator for structure-borne sound R214 and control unit for structure-borne sound J869
  170
• 4.2 Removing and installing fuel pressure sender G247
  172
• 4.3 Checking fuel pressure sender G247
  173
• 4.4 Removing and installing air mass meter G70
  177
• 5 Intake manifold
  178
• 5.1 Assembly overview - intake manifold
  178
• 5.2 Removing and installing intake manifold with fuel rail
  179
• 5.4 Removing and installing throttle valve module J338
  185
• 5.5 Cleaning throttle valve module J338
  186
• 6 Air filter
  188
• 6.1 Assembly overview - air filter
  188
• 6.2 Removing and installing air filter, engine cover
  188
• 6.3 Removing and installing air filter element
  190
• 7 Engine control unit J623
  192
• 7.1 Removing and installing engine control unit
  192
• 7.2 Removing and installing engine control unit with protective housing
  193
• Exhaust system
  197
• 1 Exhaust pipes, silencers
  197
• 1.1 Assembly overview - silencers
  197
• 1.2 Removing and installing front exhaust pipe
  199
• 1.3 Separating centre and rear silencers
  201
• 1.4 Aligning exhaust system free of stress
  202
• 1.5 Checking exhaust system for leaks
  204
• Ignition system
  205
• 1 Ignition system
  205
• 1.1 Assembly overview - ignition system
  205
• 1.2 Removing and installing ignition coils with output stage
  206
• 1.3 Test data, spark plugs
  208