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

Chapter overview

• Technical data
  1
• 1 Identification
  1
• 1.1 Engine number/engine data
  1
• 2 General information
  3
• 2.1 Numbering of cylinders
  3
• 3 Safety information
  4
• 3.1 Safety regulations for working on fuel supply
  4
• 3.3 Safety precautions when working on cooling system
  6
• 3.4 Safety precautions when working on ignition system
  7
• 3.5 Releasing high pressure in fuel system
  7
• 4 Repair instructions
  11
• 4.1 Rules for cleanliness
  11
• 4.2 Foreign objects in engine
  11
• 4.3 Contact corrosion
  11
• 4.4 Routing and attachment of lines
  12
• 4.5 Fitting radiator and condensers
  12
• Removing and installing engine
  13
• 1 Removing and installing engine
  13
• 1.1 Removing engine
  13
• 1.2 Separating engine and gearbox
  24
• 1.3 Securing engine on engine and gearbox support
  25
• 1.4 Installing engine
  27
• 2 Assembly mountings
  30
• 2.1 Assembly overview - assembly mountings
  30
• 2.2 Removing and installing engine mounting
  32
• 2.3 Supporting engine in installation position
  38
• 2.4 Adjusting assembly mountings
  44
• 2.5 Checking adjustment of assembly mountings
  46
• 3 Engine cover panel
  47
• 3.1 Removing and installing engine cover
  47
• Crankshaft group
  48
• 1 Cylinder block (pulley end)
  48
• 1.1 Assembly overview - poly V-belt drive
  48
• 1.2 Removing and installing poly-V belt
  51
• 1.3 Removing and installing tensioner for poly V-belt
  53
• 1.4 Removing and installing vibration damper
  59
• 1.5 Removing and installing bracket for ancillaries
  66
• 1.6 Renewing crankshaft oil seal - belt pulley end
  69
• 2 Cylinder block, gearbox end
  72
• 2.1 Assembly overview - cylinder block, gearbox end
  72
• 2.2 Removing and installing flywheel
  74
• 2.3 Removing and installing drive plate
  76
• 2.4 Removing and installing sealing flange on gearbox side
  79
• 3 Crankshaft
  87
• 3.1 Assembly overview - crankshaft
  87
• 3.2 Renewing needle bearing in crankshaft
  89
• 3.3 Crankshaft dimensions
  91
• 3.4 Measuring axial clearance of crankshaft
  92
• 3.5 Measuring radial clearance of crankshaft
  93
• 3.6 Allocation of main bearing shells
  93
• 3.7 Removing and installing sender wheel
  95
• 4 Balancer shaft
  97
• 4.1 Removing and installing balance shaft
  97
• 5 Pistons and conrods
  105
• 5.1 Assembly overview - pistons and conrods
  105
• 5.2 Checking pistons and cylinder bores
  107
• 5.3 Separating new conrod
  109
• Cylinder head, valve gear
  111
• 1 Cylinder head
  111
• 1.1 Assembly overview - cylinder head
  111
• 1.2 Removing and installing cylinder head
  115
• 1.3 Removing and installing vacuum pump
  136
• 1.4 Checking compression
  138
• 2 Cover for timing chain
  140
• 2.1 Assembly overview - cover for timing chain
  140
• 2.2 Removing and installing timing chain cover
  142
• 3 Chain drive
  154
• 3.1 Assembly overview - camshaft timing chains
  154
• 3.2 Assembly overview - drive chain for balance shaft
  156
• 3.3 Removing and installing camshaft timing chain
  159
• 3.4 Removing and installing drive chain for balance shaft
  170
• 3.5 Checking valve timing
  174
• 4 Valve gear
  177
• 4.1 Assembly overview - valve gear
  177
• 4.2 Measuring axial play of camshaft
  179
• 4.3 Removing and installing camshaft
  180
• 4.4 Removing and installing valve stem oil seals
  190
• 4.5 Removing and installing camshaft control valve 1 N205
  196
• 5 Inlet and exhaust valves
  198
• 5.1 Checking valve guides
  198
• 5.2 Valve dimensions
  199
• Lubrication
  200
• 1 Sump, oil pump
  200
• 1.1 Assembly overview - sump/oil pump
  200
• 1.2 Removing and installing lower part of sump
  203
• 1.3 Removing and installing upper part of sump
  206
• 1.4 Removing and installing oil pump
  213
• 1.5 Engine oil:
  215
• 2 Engine oil cooler
  217
• 2.1 Removing and installing engine oil cooler
  217
• 3 Crankcase ventilation
  221
• 3.1 Removing and installing oil separator
  221
• 4 Oil filter, oil pressure switch
  223
• 4.1 Checking oil pressure and oil pressure switch
  223
• 4.2 Assembly overview - oil filter housing, oil pressure switch
  229
• 4.3 Removing and installing oil pressure switch F22
  232
• 4.4 Removing and installing oil pressure switch for reduced oil pressure F378
  233
• 4.5 Removing and installing oil pressure regulating valve N428
  234
• Cooling
  235
• 1 Cooling system/coolant
  235
• 1.1 Connection diagram - coolant hoses
  235
• 1.2 Checking cooling system for leaks
  237
• 1.3 Draining and adding coolant
  240
• 2 Coolant pump, regulation of cooling system
  246
• 2.1 Assembly overview - coolant pump, thermostat
  246
• 2.2 Assembly overview - electric coolant pump
  249
• 2.3 Removing and installing coolant pump with thermostat housing
  250
• 2.5 Removing and installing thermostat
  256
• 2.6 Removing and installing toothed belt for coolant pump
  260
• 2.7 Renewing seal for coolant pump drive
  263
• 2.8 Removing and installing electric coolant pump
  265
• 2.9 Removing and installing coolant temperature sender
  266
• 3 Coolant pipes
  270
• 3.1 Assembly overview - coolant pipes
  270
• 3.2 Removing and installing coolant pipes
  271
• 4 Radiator, radiator fan
  278
• 4.1 Assembly overview - radiator/radiator fan
  278
• 4.2 Removing and installing radiator
  279
• 4.3 Removing and installing radiator cowl
  281
• 4.4 Removing and installing radiator fan
  283
• Turbocharging/supercharging
  284
• 1 Turbocharger
  284
• 1.1 Assembly overview - turbocharger
  284
• 1.2 Removing and installing turbocharger
  291
• 1.3 Checking vacuum unit for turbocharger
  299
• 1.4 Renewing vacuum unit for turbocharger
  301
• 2 Charge air system
  302
• 2.1 Schematic overview - charge air system
  302
• 2.2 Assembly overview - charge air system
  303
• 2.3 Checking charge air system for leaks
  304
• 2.4 Assembly overview - charge-air hose connections
  306
• Mixture preparation - injection
  308
• 1 Injection system
  308
• 1.1 Overview of fitting locations - injection system
  308
• 2 Injectors
  315
• 2.1 Assembly overview - fuel rail with injectors
  315
• 2.2 Removing and installing injectors
  317
• 2.3 Renewing seals on injectors
  321
• 2.4 Cleaning injectors
  324
• 3 High-pressure pump
  326
• 3.1 Assembly overview - high-pressure pump
  326
• 3.2 Removing and installing high-pressure pump
  328
• 4 Senders and sensors
  331
• 4.2 Removing and installing air mass meter
  333
• 4.3 Removing and installing fuel pressure sender G247
  335
• 4.4 Checking fuel pressure sender G247
  337
• 5 Intake manifold
  341
• 5.1 Assembly overview – intake manifold
  341
• 5.2 Removing and installing intake manifold with fuel rail
  344
• 5.3 Removing and installing throttle valve module
  352
• 5.4 Cleaning throttle valve module
  354
• 5.5 Checking intake manifold change-over
  355
• 6 Air filter
  358
• 6.1 Assembly overview - air filter housing
  358
• 6.2 Removing and installing air filter housing
  360
• 7 Engine control unit
  362
• 7.1 Removing and installing engine control unit J623
  362
• Exhaust system
  365
• 1 Exhaust pipes and silencers
  365
• 1.1 Assembly overview – silencers
  365
• 1.2 Removing and installing front exhaust pipe
  371
• 1.3 Separating exhaust pipes from silencers
  374
• 1.4 Aligning exhaust system free of stress
  376
• 1.5 Checking exhaust system for leaks
  378
• 2 Secondary air system
  380
• 2.1 Assembly overview - secondary air system
  380
• 2.2 Removing and installing secondary air pump motor V101
  380
• 2.3 Removing and installing secondary air inlet valve N112
  381
• 3 Exhaust manifold
  384
• Ignition system
  385
• 1 Ignition system
  385
• 1.1 Assembly overview - ignition system
  385
• 1.2 Removing and installing ignition coils with output stage
  387
• 1.3 Removing and installing knock sensor
  389
• 1.4 Removing and installing engine speed sender G28
  390
• 1.5 Test data, spark plugs
  391