4-cylinder Injection engine (2.0 l engine, direct injection)

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Engine number
  1
• 1.2 Engine data
  1
• Removing and installing engine
  2
• 1 Removing and installing engine
  2
• 1.1 Removing engine
  2
• 1.2 Fastening the engine to the assembly stand
  12
• 1.3 Installing engine
  14
• 1.4 Checking and adjusting assembly mounting
  16
• 1.5 Assembly mounting - Torque settings
  19
• Crankshaft group
  21
• 1 Dismantling and assembling engine
  21
• 1.1 Poly V-belt drive - Assembly overview
  21
• 1.2 Toothed belt drive - Assembly overview
  23
• 1.3 Cylinder block - Assembly overview
  24
• 1.4 Removing and installing poly V-belt
  25
• 2 Sealing flanges and flywheel/drive plate
  28
• 2.1 Sealing flanges - Assembly overview
  28
• 2.2 Renewing crankshaft oil seal - belt pulley end
  29
• 2.3 Removing and installing sealing flange -belt pulley end-
  31
• 2.4 Removing and installing sealing flange -gearbox side-
  34
• 2.5 Removing and installing flywheel
  35
• 2.6 Removing and installing drive plate
  35
• 3 Removing and installing crankshaft
  38
• 3.1 Crankshaft - Assembly overview
  38
• 3.2 Removing and installing sender wheel
  40
• 3.3 Crankshaft dimensions
  40
• 3.4 Marking on crankshaft bearing top
  40
• 4 Dismantling and assembling pistons and conrods
  41
• 4.1 Pistons and conrods - Assembly overview
  41
• 4.2 Check pistons, piston rings and cylinder bores
  42
• 4.3 Piston and cylinder dimensions
  44
• Cylinder head, valve gear
  45
• 1 Cylinder head
  45
• 1.1 Cylinder head - Assembly overview
  45
• 1.2 Removing and installing cylinder head cover
  47
• 1.3 Removing and installing cylinder head
  48
• 1.4 Removing and installing toothed belt
  55
• 1.5 Check compression pressures
  63
• 2 Repairing valve gear
  66
• 2.1 Valve gear - Assembly overview
  66
• 2.2 Valve dimensions
  68
• 2.3 Checking valve guides
  68
• 2.4 Renewing valve stem seals
  69
• 2.5 Renewing exhaust camshaft seal
  73
• 2.6 Removing and installing camshaft adjuster
  76
• 2.7 Removing and installing camshafts
  79
• Lubrication
  83
• 1 Parts of the lubrication system
  83
• 1.1 Engine oil
  83
• 1.2 Parts of the lubrication system - Assembly overview
  84
• 1.3 Draining oil filter housing
  89
• 1.4 Removing and installing oil sump
  90
• 1.5 Removing and installing oil pump balancer shaft gear assembly
  92
• 1.6 Removing and installing oil filter bracket
  97
• 1.7 Checking oil pressure and oil pressure switch
  98
• Cooling system
  101
• 1 Removing and installing parts of cooling system
  101
• 1.1 Parts of cooling system - engine side - Assembly overview
  101
• 1.2 Parts of cooling system - body side - Assembly overview
  103
• 1.3 Coolant hose schematic diagram
  104
• 1.4 Assembly overview - thermostat housing with thermostat
  105
• 1.5 Draining and filling coolant
  106
• 1.6 Removing and installing coolant pump
  109
• 1.7 Removing and installing coolant pipe
  111
• 1.8 Removing and installing map-controlled engine cooling thermostat F265
  112
• 1.9 Checking map-controlled engine cooling thermostat F265
  114
• 1.10 Removing and installing radiator fan V7 and radiator fan 2 V177
  115
• 1.11 Removing and installing radiator
  117
• 1.12 Check cooling system for leaks:
  121
• Fuel supply system
  123
• 1 Parts of fuel supply system
  123
• 1.1 Safety precautions when working on fuel supply system
  123
• 1.2 Rules for cleanliness
  123
• 1.3 Fuel tank - Assembly overview
  124
• 1.4 Emptying fuel tank
  126
• 1.5 Removing and installing fuel tank
  128
• 1.6 Fuel filter with attachments - Assembly overview
  130
• 1.7 Removing and installing fuel filter
  131
• 2 Repairing fuel supply
  134
• 2.1 Safety precautions when working on fuel supply system
  134
• 2.2 Rules for cleanliness
  134
• 2.3 Removing and installing fuel delivery unit
  135
• 2.4 Removing and installing fuel gauge sender G
  137
• 2.5 Checking fuel pump
  137
• 2.6 High-pressure pump - Assembly overview
  147
• 2.7 Removing and installing high-pressure pump
  148
• 3 Electronic power control (EPC)
  151
• 3.1 Function of EPC system
  151
• 3.2 Accelerator pedal module - Assembly overview
  151
• 3.3 Removing and installing accelerator pedal module
  152
• 4 Active charcoal filter system
  154
• 4.1 Function
  154
• 4.2 Assembly overview - active charcoal filter system
  154
• 4.3 Checking fuel tank breather
  155
• Mixture preparation, Injection
  157
• 1 Servicing injection system
  157
• 1.1 General notes on injection
  157
• 1.2 Safety precautions
  158
• 1.3 Rules for cleanliness
  158
• 1.4 Technical data
  159
• 1.5 Fitting locations overview
  159
• 1.6 Intake manifold - Assembly overview
  167
• 1.7 Assembly overview - suction jet pump
  169
• 1.8 Assembly overview - fuel rail with intake manifold flap motor V157
  170
• 1.9 Air filter - Assembly overview
  171
• 1.10 Removing and installing intake manifold
  172
• 1.11 Removing and installing fuel rail with intake manifold flaps
  173
• 1.12 Removing and installing injectors
  174
• 1.13 Renewing Teflon seal on injector
  176
• 1.14 Cleaning throttle valve module J338
  179
• 2 Checking components
  180
• 2.1 Checking intake manifold change-over
  180
• 3 Engine control unit
  182
• 3.1 Reading and erasing engine control unit fault memory
  182
• 3.2 Removing and installing engine control unit
  183
• Exhaust system
  187
• 1 Removing and installing parts of exhaust system
  187
• 1.2 Assembly overview - exhaust manifold, engine code BLY
  190
• 1.3 Removing and installing exhaust manifold
  190
• 1.4 Assembly overview - exhaust system, engine code BLR
  195
• 1.5 Assembly overview - exhaust system, engine code BLY
  197
• 1.6 Removing and installing front exhaust pipe with catalytic converter
  198
• 1.7 Connecting and disconnecting front and rear silencers
  200
• 1.8 Aligning exhaust system free of stress
  202
• 2 Exhaust gas recirculation system - engine code BLR
  204
• 2.1 Assembly overview - Exhaust gas recirculation system
  204
• 2.2 Removing and installing upper connecting pipe for exhaust gas recirculation valve
  205
• Ignition system
  207
• 1 Repairing ignition system
  207
• 1.1 General notes on ignition system
  207
• 1.2 Safety precautions
  207
• 1.3 Assembly overview - ignition system
  207
• 1.4 Removing and installing ignition coils with output stage
  208
• 1.5 Spark plugs
  209