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

Chapter overview

• Technical data
  1
• 1 Identification
  1
• 1.1 Engine number/engine data
  1
• 2 Safety information
  2
• 2.1 Safety regulations for working on fuel supply
  2
• 2.2 Releasing pressure in high-pressure system
  3
• 2.3 Safety measures for vehicles with Start/Stop system
  3
• 2.5 Safety precautions when working on the cooling system
  4
• 2.6 Safety precautions when working on ignition system
  5
• 3 Repair instructions
  6
• 3.1 Rules for cleanliness when working on fuel system
  6
• 3.2 Rules for cleanliness when working on charge air system
  6
• 3.3 General notes on ignition system
  7
• 3.4 General notes on the lubrication system
  7
• 3.5 Notes on hose connections with screw-type clips
  7
• 3.6 Foreign objects in engine
  8
• 3.7 Contact corrosion
  8
• 3.8 Routing and attachment of lines
  8
• 3.9 Fitting radiator and condensers
  9
• 3.10 Checking vacuum system
  9
• Removing and installing engine
  10
• 1 Removing and installing engine
  10
• 1.1 Removing engine
  10
• 1.2 Securing engine on engine and gearbox support
  21
• 1.3 Installing engine
  22
• 2 Assembly mountings
  24
• 2.1 Assembly overview - assembly mountings
  24
• 2.2 Supporting engine in installation position
  29
• 2.3 Removing and installing engine mounting
  30
• 2.4 Removing and installing engine mounting
  31
• Crankshaft group
  32
• 1 Cylinder block (pulley end)
  32
• 1.1 Assembly overview - poly V-belt drive
  32
• 1.2 Removing and installing poly-V belt
  34
• 1.3 Removing and installing tensioner for poly V-belt
  36
• 1.4 Removing and installing vibration damper
  37
• 1.5 Removing and installing bracket for ancillaries
  42
• 1.6 Renewing crankshaft oil seal - belt pulley end
  44
• 1.7 Removing and installing engine support
  46
• 2 Cylinder block, gearbox end
  48
• 2.1 Assembly overview - flywheel
  48
• 2.2 Removing and installing flywheel
  49
• 2.3 Removing and installing sealing flange on gearbox side
  50
• 2.4 Renewing needle bearing
  53
• 3 Crankshaft
  56
• 3.1 Assembly overview - crankshaft
  56
• 3.2 Crankshaft dimensions
  57
• 3.3 Measuring axial clearance of crankshaft
  57
• 3.4 Measuring radial clearance of crankshaft
  58
• 3.5 Allocation of main bearing shells
  59
• 3.6 Removing and installing sender wheel
  60
• 4 Balancer shaft
  61
• 4.1 Renewing balancer shaft for inlet camshaft
  61
• 4.2 Renewing balancer shaft for exhaust camshaft
  64
• 5 Pistons and conrods
  68
• 5.1 Assembly overview - pistons and conrods
  68
• 5.2 Removing and installing pistons
  69
• 5.3 Checking pistons and cylinder bores
  71
• 5.4 Separating new conrod
  72
• 5.5 Checking radial clearance of conrods
  73
• Cylinder head, valve gear
  74
• 1 Cylinder head
  74
• 1.1 Assembly overview - cylinder head
  74
• 1.2 Removing and installing cylinder head
  77
• 1.3 Checking compression
  86
• 1.4 Removing and installing vacuum pump
  88
• 2 Cover for timing chain
  90
• 2.1 Assembly overview - cover for timing chain
  90
• 2.2 Removing and installing upper timing chain cover
  92
• 2.3 Removing and installing timing chain cover (bottom)
  93
• 3 Chain drive
  97
• 3.1 Assembly overview - balancer shaft timing chain
  97
• 3.2 Assembly overview - camshaft timing chains
  99
• 3.3 Removing and installing camshaft timing chain
  100
• 3.4 Removing and installing balance shaft timing chain
  117
• 3.5 Checking valve timing
  119
• 4 Valve gear
  120
• 4.1 Assembly overview - valve gear
  120
• 4.2 Removing and installing camshafts
  122
• 4.3 Removing and installing actuator for camshaft adjustment F366 / F373
  132
• 4.4 Removing and installing camshaft control valve 1 N205
  132
• 4.5 Renewing valve stem seals with cylinder head installed
  132
• 4.6 Renewing valve stem seals with cylinder head removed
  136
• 4.7 Measuring axial clearance of camshaft
  140
• 5 Inlet and exhaust valves
  142
• 5.1 Checking valve guides
  142
• 5.2 Valve dimensions
  143
• Lubrication
  144
• 1 Sump, oil pump
  144
• 1.1 Removing and installing sump
  144
• 1.2 Removing and installing upper part of sump
  146
• 1.3 Removing and installing oil pump
  151
• 1.4 Engine oil:
  152
• 1.5 Removing and installing oil level and oil temperature sender G266
  153
• 1.6 Measuring oil consumption
  153
• 2 Engine oil cooler
  154
• 2.1 Assembly overview - engine oil cooler
  154
• 2.2 Removing and installing engine oil cooler
  155
• 3 Crankcase ventilation
  157
• 3.1 Removing and installing crankcase breather system
  157
• 4 Oil filter, oil pressure switch
  158
• 4.1 Removing and installing oil pressure switch F22
  158
• 4.2 Checking oil pressure
  158
• Cooling
  160
• 1 Cooling system/coolant
  160
• 1.1 Fitting location overview - cooling system
  160
• 1.2 Checking cooling system for leaks
  161
• 1.3 Draining and adding coolant
  163
• 2 Coolant pump, regulation of cooling system
  171
• 2.1 Assembly overview - coolant pump, thermostat
  171
• 2.2 Removing and installing continued coolant circulation pump V51
  172
• 2.3 Removing and installing 3/2-way valve
  174
• 2.4 Removing and installing coolant pump
  175
• 2.5 Removing and installing thermostat
  178
• 2.6 Removing and installing toothed belt for coolant pump
  179
• 2.7 Renewing oil seal for coolant pump drive
  181
• 2.8 Removing and installing coolant temperature sender G62
  182
• 2.9 Removing and installing radiator outlet coolant temperature sender G83
  183
• 3 Radiator, radiator fan
  185
• 3.1 Assembly overview - radiator cowl and radiator fan V7
  185
• 3.2 Removing and installing radiator
  185
• 3.3 Removing and installing radiator cowl with radiator fan V7
  190
• Turbocharging/supercharging
  192
• 1 Exhaust turbocharger
  192
• 1.1 Assembly overview - turbocharger
  192
• 1.2 Removing and installing turbocharger
  195
• 2 Charge air system
  201
• 2.1 Assembly overview - charge air system
  201
• 2.2 Assembly overview - charge-air hose connections
  202
• 2.3 Removing and installing charge air cooler
  203
• 2.4 Removing and installing charge pressure sender G31
  204
• 2.5 Checking charge air system for leaks
  205
• Mixture preparation - injection
  208
• 1 Injection system
  208
• 1.1 Overview of fitting locations - injection system
  208
• 2 Vacuum system
  210
• 2.1 Connection diagram - vacuum system
  210
• 3 Air filter
  211
• 3.1 Assembly overview - air filter housing
  211
• 3.2 Removing and installing air filter housing
  212
• 4 Intake manifold
  214
• 4.1 Assembly overview – intake manifold with fuel rail
  214
• 4.2 Removing and installing intake manifold upper part
  215
• 4.3 Removing and installing lower part of intake manifold
  217
• 4.4 Removing and installing throttle valve module J338
  218
• 4.5 Cleaning throttle valve module J338
  219
• 4.6 Checking intake manifold change-over
  220
• 5 Injectors
  222
• 5.1 Removing and installing injectors
  222
• 5.2 Renewing seals on injectors
  224
• 5.3 Cleaning injectors
  226
• 6 Senders and sensors
  228
• 6.1 Removing and installing air mass meter G70
  228
• 6.2 Removing and installing fuel pressure sender G247
  229
• 7 Engine control unit
  230
• 7.1 Removing and installing engine control unit J623
  230
• 7.2 Wiring and component check with test box V.A.G 1598/42
  230
• 8 High-pressure pump
  234
• 8.1 Assembly overview - high-pressure pump
  234
• 8.2 Removing and installing high-pressure pump
  235
• 9 Lambda probe
  238
• 9.1 Overview - Lambda probes
  238
• 9.2 Removing and installing Lambda probe G39 before catalytic converter
  239
• 9.3 Removing and installing Lambda probe after catalytic converter G130
  240
• Exhaust system
  242
• 1 Exhaust pipes and silencers
  242
• 1.1 Removing and installing centre silencer
  242
• 1.2 Removing and installing rear silencer
  243
• 1.3 Aligning exhaust system free of stress
  245
• 1.4 Check exhaust system for leaks
  246
• 1.5 Installation position of clamp
  246
• 2 Exhaust gas cleaning
  248
• 2.1 Removing and installing starter catalytic converter
  248
• 2.2 Removing and installing secondary catalytic converter
  249
• Ignition system
  251
• 1 Ignition system
  251
• 1.1 Assembly overview - ignition system
  251
• 1.2 Removing and installing ignition coils with output stage
  252
• 1.3 Removing and installing spark plugs
  253
• 1.4 Removing and installing knock sensor 1 G61
  255
• 1.5 Removing and installing Hall sender G40
  256
• 1.6 Removing and installing engine speed sender G28
  256
• 1.7 Test data, spark plugs
  256