4-cylinder injection engine (2.0 l engine)

Chapter overview

• Technical data
  1
• 1 Identification
  1
• 1.1 Engine number/engine data
  1
• 2 Safety information
  2
• 2.1 Safety precautions when working on the cooling system
  2
• 2.2 Safety measures when working on fuel supply
  3
• 2.3 Safety precautions when working on injection system
  4
• 2.4 Safety precautions when working on ignition system
  5
• 3 Repair instructions
  7
• 3.1 Rules for cleanliness when working on fuel supply system/injection system
  7
• 3.2 General notes on injection
  7
• 3.3 General notes on ignition system
  7
• Removing and installing engine
  9
• 1 Removing and installing engine
  9
• 1.1 Removing engine
  9
• 1.2 Securing engine to assembly stand
  16
• 1.3 Installing engine
  16
• 2 Assembly mountings
  18
• 2.1 Assembly overview - assembly mountings
  18
• Crankshaft group
  19
• 1 Cylinder block (pulley end)
  19
• 1.1 Assembly overview - poly V-belt drive
  19
• 1.2 Assembly overview - cylinder block (pulley end)
  20
• 1.3 Assembly overview - cylinder block
  21
• 1.4 Removing and installing poly-V belt
  22
• 1.5 Removing and installing bracket for ancillaries
  24
• 1.6 Renewing crankshaft oil seal - belt pulley end
  24
• 1.7 Removing and installing sealing flange on pulley end
  26
• 2 Cylinder block, gearbox end
  30
• 2.1 Assembly overview - cylinder block, gearbox end
  30
• 3 Crankshaft
  32
• 3.1 Assembly overview - crankshaft
  32
• 3.2 Removing and installing sender wheel
  34
• 3.3 Crankshaft dimensions
  34
• 4 Pistons and conrods
  35
• 4.1 Assembly overview - pistons and conrods
  35
• 4.2 Piston and cylinder dimensions
  37
• 4.3 Checking pistons and cylinder bores
  37
• Cylinder head, valve gear
  38
• 1 Cylinder head
  38
• 1.1 Assembly overview - cylinder head
  38
• 1.2 Removing and installing cylinder head
  40
• 1.3 Checking compression
  45
• 2 Toothed belt drive
  49
• 2.1 Removing and installing toothed belt
  49
• 2.2 Removing and installing toothed belt, 2010 ►
  53
• 2.3 Checking semi-automatic toothed belt tensioner
  59
• 3 Valve gear
  60
• 3.1 Assembly overview - valve gear
  60
• 3.2 Measuring axial play of camshaft
  63
• 3.3 Removing and installing camshaft oil seal
  63
• 3.4 Removing and installing camshaft
  65
• 3.5 Removing and installing valve stem seals
  68
• 3.6 Checking hydraulic compensation elements
  71
• 4 Inlet and exhaust valves
  73
• 4.1 Reworking valve seats
  73
• 4.2 Checking valve guides
  74
• 4.3 Valve dimensions
  75
• Lubrication
  76
• 1 Sump, oil pump
  76
• 1.1 Assembly overview - sump/oil pump
  76
• 1.2 Removing and installing sump
  77
• 1.3 Removing and installing oil pump
  80
• 1.4 Engine oil:
  80
• 2 Oil filter, oil pressure switch
  81
• 2.1 Assembly overview - oil filter/oil pressure switch
  81
• 2.2 Checking oil pressure and oil pressure switch
  82
• 2.3 Measuring oil consumption
  84
• Cooling
  85
• 1 Cooling system/coolant
  85
• 1.1 Connection diagram - coolant hoses
  85
• 1.2 Coolant hose schematic diagram, 2010 ►
  86
• 1.3 Coolant hose schematic diagram for vehicles with an additional heat exchanger, 2010 ►
  87
• 1.5 Coolant hose schematic diagram, vehicles with auxiliary heater, 2010 ►
  89
• 1.7 Checking cooling system for leaks
  90
• 1.8 Draining and adding coolant
  92
• 2 Coolant pump, regulation of cooling system
  101
• 2.1 Assembly overview - coolant pump, thermostat
  101
• 2.2 Assembly overview - Y thermostat
  103
• 2.3 Removing and installing coolant pump
  104
• 2.4 Removing and installing thermostat
  105
• 2.5 Testing Y-thermostat
  107
• 3 Radiator, radiator fan
  109
• 3.1 Assembly overview - radiator/radiator fan
  109
• 3.2 Assembly overview - radiator, radiator fan, 2010 ►
  110
• 3.3 Assembly overview - radiator cowl with radiator fan V7 and right radiator fan V35
  111
• 3.4 Assembly overview - radiator cowl with radiator fan V7 , 2010 ►
  112
• 3.5 Removing and installing radiator
  113
• 3.6 Removing and installing radiator cowl with radiator fan V7 , 2010 ►
  114
• Mixture preparation - injection
  116
• 1 Air filter
  116
• 1.1 Assembly overview - air filter housing
  116
• 2 Intake manifold
  117
• 2.1 Assembly overview - intake manifold
  117
• 2.2 Assembly overview - lower part of intake manifold with fuel rail
  119
• 3 Injectors
  120
• 3.1 Removing and installing injectors
  120
• 3.2 Checking injectors
  121
• 3.3 Checking quantity injected
  124
• 4 Senders and sensors
  126
• 4.1 Checking fuel pressure regulator and holding pressure
  126
• 5 Engine control unit
  129
• 5.1 Removing and installing engine (motor) control unit J623
  129
• Exhaust system
  130
• 1 Exhaust pipes and silencers
  130
• 1.1 Assembly overview - silencers
  130
• 1.2 Separating exhaust pipes from silencers
  130
• 2 Emission control
  132
• 2.1 Assembly overview - emission control
  132
• 3 Exhaust gas recirculation
  134
• 3.1 Assembly overview - exhaust gas recirculation
  134
• 4 Secondary air system
  135
• 4.1 Function
  135
• 4.2 Assembly overview - secondary air system
  135
• 4.3 Checking combination valve
  136
• Ignition system
  137
• 1 Ignition system
  137
• 1.1 Assembly overview - ignition system
  137
• 1.2 Removing and installing spark plugs
  138
• 1.3 Test data, spark plugs
  139