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

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Engine number
  1
• 1.2 Engine data
  1
• Removing and installing engine
  2
• 1 Removing and installing engine
  2
• 1.1 Removing engine
  2
• 1.2 Installing engine
  9
• Crankshaft group
  13
• 1 Dismantling and assembling engine
  13
• 1.1 Assembly overview - dismantling and assembling engine
  14
• 1.2 Removing and installing poly V-belt
  18
• 2 Sealing flange and flywheel
  20
• 2.1 Assembly overview - sealing flange
  20
• 2.2 Renewing crankshaft oil seal - pulley end
  21
• 2.3 Removing and installing sealing flange - pulley end
  24
• 2.4 Removing and installing crankshaft sealing flange - flywheel end
  26
• 2.5 Removing and installing flywheel
  27
• 3 Crankshaft
  29
• 3.1 Assembly overview - crankshaft
  29
• 3.2 Crankshaft dimensions
  30
• 4 Pistons and conrods
  32
• 4.1 Assembly overview - pistons and conrods
  32
• 4.2 Checking pistons, piston rings and cylinder bores
  33
• 4.3 Piston and cylinder dimensions
  35
• Cylinder head, valve gear
  36
• 1 Cylinder head
  36
• 1.1 Assembly overview - cylinder head
  37
• 1.2 Removing and installing cylinder head cover
  38
• 1.3 Removing and installing cylinder head
  40
• 1.4 Removing and installing toothed belt
  44
• 1.5 Checking compression
  52
• 2 Valve gear
  54
• 2.1 Assembly overview - valve gear
  55
• 2.2 Valve dimensions
  56
• 2.3 Checking valve guides
  56
• 2.4 Renewing valve stem seals
  57
• 2.5 Renewing exhaust camshaft oil seal
  62
• 2.6 Removing and installing camshaft adjuster
  64
• 2.7 Removing and installing inlet camshaft control valve 1 N205
  67
• 2.8 Removing and installing camshafts
  68
• Lubrication
  72
• 1 Parts of lubrication system
  72
• 1.1 Engine oil
  72
• 1.2 Assembly overview - parts of lubrication system
  73
• 1.3 Draining oil filter housing
  77
• 1.4 Removing and installing sump
  78
• 1.5 Removing and installing oil pump with balancer shaft gear assembly
  80
• 1.6 Removing and installing oil filter bracket
  84
• 1.7 Checking oil pressure and oil pressure switch
  86
• Cooling
  88
• 1 Parts of cooling system
  88
• 1.1 Assembly overview - parts of cooling system, engine side
  89
• 1.2 Assembly overview - parts of cooling system, body side
  90
• 1.3 Coolant hose schematic diagram
  91
• 1.4 Draining and filling coolant
  92
• 1.5 Removing and installing coolant pump
  95
• 1.6 Removing and installing coolant pipe
  96
• 1.7 Removing and installing coolant distributor housing with thermostat
  97
• 1.8 Removing and installing radiator fan V7 and radiator fan 2 V177
  98
• 1.9 Removing and installing radiator
  100
• 1.10 Checking cooling system for leaks
  101
• Fuel supply system
  103
• 1 Safety precautions
  103
• 1.1 Safety precautions when working on fuel supply system
  103
• 1.2 Releasing pressure in high-pressure section
  103
• 2 Fuel tank
  105
• 2.1 Rules for cleanliness
  105
• 2.2 Assembly overview - fuel tank
  106
• 2.3 Emptying fuel tank
  107
• 2.4 Removing and installing fuel tank
  109
• 3 Repairing fuel supply system
  113
• 3.1 Safety precautions when working on fuel supply system
  113
• 3.2 Rules for cleanliness
  114
• 3.3 Removing and installing fuel delivery unit
  114
• 3.4 Removing and installing fuel gauge sender G
  116
• 3.5 Checking fuel pump
  117
• 3.6 Assembly overview - high-pressure pump
  126
• 3.7 Removing and installing high-pressure pump
  126
• 4 Electronic power control (EPC)
  129
• 4.1 Function of EPC system
  129
• 4.2 Assembly overview - accelerator pedal module
  130
• 4.3 Removing and installing accelerator pedal module
  130
• 5 Activated charcoal filter system
  132
• 5.1 Function
  132
• 5.2 Assembly overview - activated charcoal filter system
  133
• 5.3 Checking fuel tank breather
  133
• Mixture preparation - injection
  136
• 1 Injection system
  136
• 1.1 General notes on injection
  136
• 1.2 Safety precautions
  137
• 1.3 Rules for cleanliness
  137
• 1.4 Technical data
  138
• 1.5 Assembly overview - intake manifold
  139
• 1.6 Assembly overview - fuel rail with intake manifold flap motor V157
  141
• 1.7 Assembly overview - air filter
  142
• 1.8 Removing and installing intake manifold
  142
• 1.9 Removing and installing fuel rail with intake manifold flaps
  144
• 1.10 Removing and installing injectors
  146
• 1.11 Renewing Teflon seal on injector
  147
• 1.12 Cleaning throttle valve module J338
  150
• 2 Checking components
  151
• 2.1 Checking intake manifold change-over
  151
• 3 Engine control unit
  153
• 3.1 Removing and installing engine control unit
  153
• 3.2 Removing and installing anti-theft engine control unit
  153
• Exhaust system
  156
• 1 Parts of the exhaust system
  156
• 1.2 Assembly overview - exhaust system, engine code BVY
  158
• 1.3 Assembly overview - exhaust manifold, engine code BVZ
  160
• 1.4 Assembly overview - exhaust system, engine code BVZ
  161
• 1.5 Separating centre and rear silencers
  162
• 1.6 Aligning exhaust system free of stress
  163
• 1.7 Removing and installing front exhaust pipe with catalytic converter
  164
• 1.8 Removing and installing exhaust manifold
  165
• 2 Exhaust gas recirculation system, engine code BVY
  170
• 2.1 Assembly overview - exhaust gas recirculation system
  171
• Ignition system
  172
• 1 Repairing ignition system
  172
• 1.1 General notes on ignition system
  172
• 1.2 Safety precautions
  172
• 1.3 Assembly overview - ignition system
  173
• 1.4 Removing and installing ignition coils with output stage
  173
• 1.5 Spark plug test data
  174