4-cylinder injection engine (2.0 l engine, chain drive)

Chapter overview

• Technical data
  1
• 1 Safety precautions
  1
• 1.1 Safety regulations for working on fuel supply
  1
• 1.2 Releasing pressure in high-pressure area
  2
• 2 Identification
  6
• 2.1 Engine number/engine data
  6
• 3 Repair instructions
  8
• 3.1 Rules for cleanliness
  8
• Removing and installing engine
  9
• 1 Removing and installing engine
  9
• 1.1 Removing engine
  9
• 1.2 Separating engine and gearbox
  20
• 1.3 Securing engine on engine and gearbox support
  21
• 1.4 Installing engine
  23
• 2 Assembly mountings
  26
• 2.1 Assembly overview - assembly mountings
  26
• 2.2 Checking adjustment of assembly mountings (engine and gearbox mountings)
  28
• 2.3 Checking adjustment of assembly mountings (engine and gearbox mountings)
  28
• 3 Motor cover
  32
• 3.1 Removing and installing engine cover
  32
• Crankshaft group
  33
• 1 Cylinder block (pulley end)
  33
• 1.1 Assembly overview - poly V-belt drive
  33
• 1.2 Removing and installing poly-V belt
  35
• 1.3 Removing and installing tensioner for poly V-belt
  36
• 1.4 Removing and installing vibration damper
  39
• 1.5 Renewing seal for vibration damper
  46
• 1.6 Removing and installing bracket for ancillaries
  47
• 2 Cylinder block, gearbox end
  50
• 2.1 Assembly overview - cylinder block, gearbox end
  50
• 2.2 Removing and installing flywheel
  51
• 2.3 Removing and installing sealing flange on gearbox side
  53
• 3 Crankshaft
  55
• 3.1 Assembly overview - crankshaft
  55
• 3.2 Crankshaft dimensions
  56
• 3.3 Allocation of main bearing shells
  57
• 3.4 Renewing needle bearing in crankshaft
  58
• 3.5 Measuring axial clearance of crankshaft
  60
• 3.6 Measuring radial clearance of crankshaft
  61
• 3.7 Removing and installing sender wheel
  62
• 4 Pistons and conrods
  63
• 4.1 Assembly overview - pistons and conrods
  63
• 4.2 Checking pistons and cylinder bores
  64
• 4.3 Separating new conrod
  67
• Cylinder head, valve gear
  68
• 1 Cylinder head
  68
• 1.1 Assembly overview - cylinder head
  68
• 1.2 Removing and installing cylinder head
  72
• 1.3 Removing and installing vacuum pump
  90
• 1.4 Checking compression
  91
• 2 Cover for timing chain
  94
• 2.1 Assembly overview - cover for timing chain
  94
• 2.2 Removing and installing timing chain cover (top)
  96
• 2.3 Removing and installing timing chain cover (bottom)
  97
• 3 Chain drive
  106
• 3.1 Assembly overview - camshaft timing chains
  106
• 3.2 Assembly overview - drive chain for balance shaft
  108
• 3.3 Removing and installing camshaft timing chain
  110
• 3.4 Removing and installing drive chain for balance shaft
  123
• 3.5 Removing and installing balance shaft for inlet camshaft
  125
• 3.6 Removing and installing balance shaft for exhaust camshaft
  128
• 3.7 Checking valve timing
  131
• 4 Valve gear
  134
• 4.1 Assembly overview - valve gear
  134
• 4.2 Measuring axial play of camshaft
  136
• 4.3 Removing and installing camshaft
  137
• 4.4 Removing and installing camshaft control valve 1 N205
  146
• 4.5 Removing and installing valve stem seals
  147
• 5 Inlet and exhaust valves
  152
• 5.1 Checking valve guides
  152
• Lubrication
  153
• 1 Sump, oil pump
  153
• 1.1 Assembly overview - sump/oil pump
  153
• 1.2 Engine oil:
  155
• 1.3 Removing and installing coarse oil separator
  156
• 1.4 Removing and installing lower part of sump
  157
• 1.5 Removing and installing upper part of sump
  159
• 1.6 Removing and installing oil pump
  164
• 2 Oil filter, oil pressure switch
  167
• 2.1 Assembly overview - oil filter housing, oil pressure switch F1
  167
• 2.3 Removing and installing engine oil cooler
  169
• 2.4 Checking oil pressure and oil pressure switch F1
  170
• 2.5 Checking oil pressure and oil pressure switch for reduced oil pressure F378
  173
• 2.6 Removing and installing oil pressure switch F22
  176
• 2.7 Removing and installing oil pressure switch for reduced oil pressure F378
  177
• 2.8 Removing and installing oil pressure regulating valve N428
  178
• Cooling
  180
• 1 Cooling system/coolant
  180
• 1.1 Connection diagram - coolant hoses
  180
• 1.2 Checking cooling system for leaks
  182
• 1.3 Draining and adding coolant
  184
• 2 Coolant pump, regulation of cooling system
  191
• 2.1 Assembly overview - coolant pump, thermostat
  191
• 2.2 Assembly overview - electric coolant pump
  193
• 2.3 Removing and installing electric coolant pump
  193
• 2.4 Removing and installing thermostat
  195
• 2.5 Removing and installing coolant pump
  198
• 2.6 Removing and installing toothed belt for coolant pump
  199
• 2.7 Renewing seal for coolant pump drive
  201
• 2.8 Removing and installing coolant temperature sender G62
  202
• 3 Coolant pipes
  206
• 3.1 Assembly overview - coolant pipes
  206
• 3.2 Removing and installing front coolant pipes
  207
• 3.3 Removing and installing small coolant pipe
  210
• 4 Radiator, radiator fan
  212
• 4.1 Assembly overview - radiator/radiator fan
  212
• 4.2 Removing and installing radiator
  213
• 4.3 Removing and installing radiator cowl with radiator fan
  215
• 4.4 Removing and installing radiator fan V7 and radiator fan 2 V177
  216
• Fuel supply system
  218
• 1 Fuel
  218
• 1.1 Assembly overview - fuel tank
  218
• 1.2 Emptying fuel tank
  223
• 1.3 Removing and installing fuel tank
  230
• 2 Fuel delivery unit, fuel gauge sender
  233
• 2.1 Removing and installing fuel delivery unit, fuel gauge sender
  233
• 2.2 Removing and installing fuel gauge sender G
  236
• 3 Fuel filter
  238
• 3.1 Assembly overview - fuel filter
  238
• 3.2 Removing and installing fuel filter
  238
• 4 Activated charcoal filter system
  241
• 4.1 Assembly overview - activated charcoal filter system
  241
• 4.2 Schematic overview of activated charcoal filter system
  245
• 4.3 Removing and installing activated charcoal filter
  246
• 4.4 Checking fuel tank breather
  247
• 4.5 Removing and installing fuel system diagnosis pump
  249
• 4.6 Checking vacuum supply of fuel system diagnostic pump
  250
• 4.7 Checking fuel system for leaks
  252
• 4.8 Checking double non-return valve
  255
• 4.9 Leak detection in fuel system
  256
• 5 Accelerator pedal
  259
• 5.1 Assembly overview - accelerator module
  259
• 5.2 Removing and installing accelerator pedal module
  259
• 6 Fuel pump
  262
• 6.1 Checking fuel system pressurisation pump G6
  262
• Turbocharging/supercharging
  278
• 1 Exhaust turbocharger
  278
• 1.1 Assembly overview - turbocharger
  278
• 1.2 Removing and installing turbocharger
  284
• 1.3 Checking vacuum unit for turbocharger
  290
• 1.4 Renewing vacuum unit for turbocharger
  292
• 2 Charge air system
  294
• 2.1 Fitting hose connections with plug-in connectors
  294
• 2.2 Schematic overview - charge air system
  294
• 2.3 Assembly overview - charge air system
  295
• 2.4 Removing and installing charge air cooler
  296
• 2.5 Checking charge air system for leaks
  299
• Mixture preparation - injection
  302
• 1 Injection system
  302
• 1.1 Overview of fitting locations - injection system
  302
• 2 Injectors
  308
• 2.1 Removing and installing injectors
  308
• 2.2 Renewing seals on injectors
  311
• 2.3 Cleaning injectors
  313
• 3 Air filter
  315
• 3.1 Assembly overview - air filter housing
  315
• 3.2 Removing and installing air filter
  316
• 3.3 Removing and installing air filter element
  318
• 4 Intake manifold
  321
• 4.1 Assembly overview - intake manifold
  321
• 4.2 Removing and installing intake manifold with fuel rail
  323
• 4.3 Removing and installing throttle valve module J338
  330
• 4.4 Cleaning throttle valve module
  332
• 4.5 Checking intake manifold change-over
  332
• 5 Senders and sensors
  335
• 5.1 Removing and installing fuel pressure sender G247
  335
• 5.2 Checking fuel pressure sender G247
  336
• 5.3 Removing and installing air mass meter
  340
• 6 Engine (motor) control unit
  341
• 6.1 Removing and installing engine (motor) control unit J623
  341
• 7 High-pressure pump
  345
• 7.1 Assembly overview - high-pressure pump
  345
• 7.2 Assembly overview - fuel pipes and fuel rail
  346
• 7.3 Removing and installing high-pressure pump
  348
• Exhaust system
  352
• 1 Exhaust pipes and silencers
  352
• 1.1 Assembly overview - silencers
  352
• 1.2 Removing and installing front exhaust pipe
  354
• 1.3 Separating exhaust pipes from silencers
  357
• 1.4 Aligning exhaust system free of stress
  358
• 1.5 Check exhaust system for leaks
  360
• 2 Secondary air system
  361
• 2.1 Assembly overview - secondary air system
  361
• 2.2 Removing and installing secondary air pump motor V101
  361
• 2.3 Removing and installing secondary air inlet valve N112
  362
• Ignition system
  364
• 1 Ignition system
  364
• 1.1 Safety precautions
  364
• 1.2 Assembly overview - ignition system
  364
• 1.3 Test data, spark plugs
  366
• 1.4 Removing and installing ignition coils with output stage
  366
• 1.5 Removing and installing knock sensor 1 G61
  368
• 1.6 Removing and installing engine speed sender G28
  368