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

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety regulations for working on fuel supply
  1
• 1.2 Safety measures when working on vehicles with a start/stop system
  1
• 1.4 Safety precautions when working on the cooling system
  2
• 1.5 Safety precautions when working on ignition system
  2
• 1.6 Safety precautions when working on exhaust system
  3
• 2 Identification
  4
• 2.1 Engine number/engine data
  4
• 3 Repair instructions
  6
• 3.1 Rules for cleanliness
  6
• 3.2 General notes
  6
• 3.3 General repair notes
  7
• 3.4 Foreign objects in engine
  7
• 3.5 Contact corrosion
  7
• 3.6 Routing and attachment of lines
  8
• 3.7 Fitting radiator and condensers
  8
• 3.8 Checking vacuum system
  8
• Removing and installing engine
  9
• 1 Removing and installing engine
  9
• 1.1 Removing engine
  9
• 1.2 Securing engine on engine and gearbox support
  21
• 1.3 Installing engine
  23
• 2 Assembly mountings
  28
• 2.1 Assembly overview - assembly mountings
  28
• 2.2 Removing and installing engine mounting
  31
• 2.3 Removing and installing engine mounting
  33
• 2.4 Removing and installing gearbox mounting
  35
• 2.5 Supporting engine in installation position
  37
• Crankshaft group
  39
• 1 Cylinder block (pulley end)
  39
• 1.1 Assembly overview - poly V-belt drive
  39
• 1.2 Removing and installing poly-V belt
  42
• 1.3 Removing and installing tensioner for poly V-belt
  44
• 1.4 Removing and installing vibration damper
  45
• 1.5 Removing and installing bracket for ancillaries
  52
• 1.6 Renewing crankshaft oil seal - belt pulley end
  54
• 1.7 Removing and installing engine support
  57
• 2 Cylinder block, gearbox end
  61
• 2.1 Assembly overview - flywheel
  61
• 2.2 Removing and installing flywheel
  62
• 2.3 Removing and installing sealing flange on gearbox side
  64
• 2.4 Renewing needle bearing in drive plate
  68
• 3 Crankshaft
  71
• 3.1 Assembly overview - crankshaft
  71
• 3.2 Crankshaft dimensions
  73
• 3.3 Measuring axial clearance of crankshaft
  73
• 3.4 Measuring radial clearance of crankshaft
  74
• 3.5 Allocation of main bearing shells
  75
• 3.6 Removing and installing sender wheel
  77
• 4 Balancer shaft
  78
• 4.1 Assembly overview - balance shaft
  78
• 4.2 Removing and installing balance shaft
  79
• 5 Pistons and conrods
  90
• 5.1 Assembly overview - pistons and conrods
  90
• 5.2 Removing and installing pistons
  92
• 5.3 Checking pistons and cylinder bores
  93
• 5.4 Separating new conrod
  96
• 5.5 Checking radial clearance of conrods
  97
• Cylinder head, valve gear
  98
• 1 Cylinder head
  98
• 1.1 Assembly overview - cylinder head
  98
• 1.2 Removing and installing cylinder head
  102
• 1.3 Checking compression
  113
• 1.4 Removing and installing vacuum pump
  114
• 2 Cover for timing chain
  116
• 2.1 Assembly overview - cover for timing chain
  116
• 2.2 Removing and installing timing chain cover
  119
• 3 Chain drive
  124
• 3.1 Assembly overview - drive chain for balance shaft
  124
• 3.2 Assembly overview - camshaft timing chains
  127
• 3.3 Removing and installing camshaft timing chain
  129
• 3.4 Removing and installing drive chain for balance shaft
  145
• 3.5 Checking valve timing
  148
• 4 Valve gear
  150
• 4.1 Assembly overview - valve gear
  150
• 4.2 Removing and installing camshaft
  153
• 4.3 Removing and installing camshaft adjuster
  166
• 4.4 Removing and installing camshaft control valve 1 N205
  167
• 4.5 Removing and installing valve stem seals
  168
• 4.6 Measuring axial play of camshaft
  178
• 5 Inlet and exhaust valves
  180
• 5.1 Checking valve guides
  180
• 5.2 Checking valves
  181
• 5.3 Valve dimensions
  181
• Lubrication
  182
• 1 Sump, oil pump
  182
• 1.1 Removing and installing oil sump
  182
• 1.2 Removing and installing upper part of sump
  184
• 1.3 Removing and installing oil pump
  190
• 1.4 Engine oil:
  192
• 1.5 Removing and installing oil level and oil temperature sender G266
  192
• 2 Engine oil cooler
  194
• 2.1 Assembly overview - engine oil cooler
  194
• 2.2 Removing and installing engine oil cooler
  196
• 3 Crankcase ventilation
  198
• 3.1 Removing and installing oil separator
  198
• 4 Oil filter, oil pressure switch
  200
• 4.1 Removing and installing oil pressure switch F22
  200
• 4.2 Checking oil pressure
  200
• Cooling
  203
• 1 Cooling system/coolant
  203
• 1.1 Overview of fitting locations – cooling system
  203
• 1.2 Checking cooling system for leaks
  205
• 1.3 Draining and adding coolant
  207
• 2 Coolant pump, regulation of cooling system
  217
• 2.1 Assembly overview - coolant pump, thermostat
  217
• 2.2 Removing and installing coolant pump
  219
• 2.3 Removing and installing thermostat
  227
• 2.4 Removing and installing toothed belt for coolant pump
  229
• 2.5 Removing and installing coolant temperature sender G62
  231
• 2.6 Removing and installing radiator outlet coolant temperature sender G83
  232
• 2.7 Removing and installing coolant valves
  234
• 3 Radiator, radiator fan
  236
• 3.1 Assembly overview - radiator/radiator fan
  236
• 3.2 Removing and installing radiator
  236
• 3.3 Removing and installing radiator cowl with radiator fan
  242
• Turbocharging/supercharging
  244
• 1 Turbocharger
  244
• 1.1 Assembly overview - turbocharger
  244
• 1.2 Removing and installing turbocharger
  247
• 2 Charge air system
  254
• 2.1 Assembly overview - charge air system
  254
• 2.2 Removing and installing charge air cooler
  255
• 2.3 Removing and installing charge pressure sender G31
  256
• 2.4 Checking charge air system for leaks
  258
• Mixture preparation - injection
  261
• 1 Injection system
  261
• 1.1 Overview of fitting locations - injection system
  261
• 2 Vacuum system
  264
• 2.1 Connection diagram – vacuum system
  264
• 3 Injectors
  265
• 3.1 Removing and installing injectors
  265
• 3.2 Renewing seals on injectors
  266
• 3.3 Cleaning injectors
  269
• 4 Air filter
  272
• 4.1 Assembly overview - air filter housing
  272
• 4.2 Removing and installing air filter housing
  274
• 5 Intake manifold
  276
• 5.1 Assembly overview - lower part of intake manifold with fuel rail
  276
• 5.2 Removing and installing intake manifold upper part
  278
• 5.3 Removing and installing lower part of intake manifold
  280
• 5.4 Removing and installing throttle valve module J338
  282
• 5.5 Checking intake manifold change-over
  284
• 6 Senders and sensors
  287
• 6.1 Removing and installing air mass meter G70
  287
• 6.2 Removing and installing fuel pressure sender G247
  288
• 7 Engine control unit
  290
• 7.1 Removing and installing engine control unit J623
  290
• 8 High-pressure pump
  292
• 8.1 Assembly overview - high-pressure pump
  292
• 8.2 Removing and installing high-pressure pump
  294
• 9 Lambda probe
  297
• 9.1 Assembly overview - Lambda probe
  297
• 9.2 Removing and installing Lambda probe
  298
• Exhaust system
  302
• 1 Exhaust pipes and silencers
  302
• 1.1 Removing and installing centre silencer
  302
• 1.2 Removing and installing rear silencer
  303
• 1.3 Aligning exhaust system free of stress
  305
• 1.4 Checking exhaust system for leaks
  306
• 1.5 Installation position of clamp
  306
• 2 Emission control
  309
• 2.1 Removing and installing catalytic converter
  309
• Ignition system
  314
• 1 Ignition system
  314
• 1.1 Assembly overview - ignition system
  314
• 1.2 Removing and installing ignition coils with output stage
  315
• 1.3 Removing and installing knock sensor 1 G61
  318
• 1.4 Removing and installing Hall sender G40
  319
• 1.5 Removing and installing engine speed sender G28
  319
• 1.6 Test data, spark plugs
  320