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

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
  10
• Crankshaft group
  14
• 1 Dismantling and assembling engine
  14
• 1.1 Assembly overview
  15
• 1.2 Removing and installing poly-V-belt
  19
• 2 Sealing flange and flywheel
  21
• 2.1 Assembly overview - sealing flange
  21
• 2.2 Renewing crankshaft oil seal - belt pulley end
  22
• 2.3 Removing and installing sealing flange - pulley end
  25
• 2.4 Removing and installing crankshaft sealing flange - flywheel end
  27
• 2.5 Removing and installing flywheel
  28
• 3 Crankshaft
  30
• 3.1 Assembly overview - crankshaft
  31
• 3.2 Pulling needle bearing out of and driving into crankshaft
  32
• 3.3 Crankshaft dimensions
  33
• 4 Pistons and conrods
  35
• 4.1 Assembly overview - pistons and conrods
  35
• 4.2 Checking pistons, piston rings and cylinder bores
  36
• 4.3 Piston and cylinder dimensions
  38
• Cylinder head, valve gear
  39
• 1 Cylinder head
  39
• 1.1 Assembly overview - cylinder head
  40
• 1.2 Removing and installing cylinder head cover
  41
• 1.3 Removing and installing cylinder head
  43
• 1.4 Removing and installing toothed belt
  48
• 1.5 Checking compression
  57
• 2 Valve gear
  59
• 2.1 Assembly overview - valve gear
  60
• 2.2 Valve dimensions
  61
• 2.3 Checking valve guides
  61
• 2.4 Renewing valve stem oil seals
  62
• 2.5 Renewing exhaust camshaft oil seal
  66
• 2.6 Removing and installing camshaft adjuster
  68
• 2.7 Removing and installing inlet camshaft control valve 1 N205
  72
• 2.8 Removing and installing camshafts
  73
• Lubrication
  77
• 1 Parts of lubrication system
  77
• 1.1 Engine oil
  77
• 1.2 Assembly overview - parts of lubrication system
  78
• 1.3 Draining oil filter housing
  82
• 1.4 Removing and installing sump
  83
• 1.5 Removing and installing oil pump with balancer shaft gear assembly
  85
• 1.6 Removing and installing oil filter bracket
  89
• 1.7 Checking oil pressure and oil pressure switch
  90
• Cooling
  92
• 1 Parts of cooling system
  92
• 1.1 Assembly overview - parts of cooling system, engine side
  93
• 1.2 Assembly overview - coolant circulation pump V50 , engine code BWA
  94
• 1.3 Assembly overview - coolant circulation pump V50 , engine code BPY
  95
• 1.4 Assembly overview - parts of cooling system, body side
  96
• 1.5 Coolant hose schematic diagram, engine code BWA
  97
• 1.6 Coolant hose schematic diagram, engine code BPY
  98
• 1.7 Bypass thermostat
  99
• 1.8 Draining and filling coolant
  100
• 1.9 Removing and installing coolant pump
  103
• 1.10 Removing and installing coolant thermostat housing with thermostat
  106
• 1.11 Removing and installing radiator fan V7 and radiator fan 2 V177
  107
• 1.12 Removing and installing radiator
  108
• 1.13 Checking cooling system for leaks
  110
• Fuel supply system
  112
• 1 Safety precautions
  112
• 1.1 Safety precautions when working on fuel supply system and ignition system
  112
• 1.2 Reducing pressure in high pressure area
  113
• 2 Fuel tank
  115
• 2.1 Rules for cleanliness
  115
• 2.2 Assembly overview - fuel tank, engine code BPY
  116
• 2.3 Assembly overview - fuel tank, engine code BWA
  118
• 2.4 Emptying fuel tank
  119
• 2.5 Removing and installing fuel tank
  122
• 3 Repairing fuel supply system
  125
• 3.1 Safety precautions when working on fuel supply system
  125
• 3.2 Rules for cleanliness
  126
• 3.3 Removing and installing fuel delivery unit
  126
• 3.4 Removing and installing fuel gauge sender G
  128
• 3.5 Checking fuel pump
  129
• 3.6 Assembly overview - high-pressure pump
  137
• 3.7 Removing and installing high-pressure pump
  138
• 4 Electronic power control (EPC)
  140
• 4.1 Function of EPC system
  140
• 4.2 Assembly overview - accelerator module
  141
• 4.3 Removing and installing accelerator module
  141
• 5 Activated charcoal filter system, engine code BWA
  143
• 5.1 Function
  143
• 5.2 Assembly overview - activated charcoal filter system
  144
• 5.3 Checking fuel tank breather
  144
• 6 Activated charcoal filter system, engine code BPY
  147
• 6.1 Schematic diagram of activated charcoal filter system
  147
• 6.2 Assembly overview - activated charcoal filter system
  149
• 6.3 Removing and installing activated charcoal filter
  149
• 6.4 Removing and installing fuel system diagnostic pump V144
  151
• 6.5 Checking fuel system for leaks
  152
• Turbocharging/supercharging
  155
• 1 Turbocharger
  155
• 1.1 Rules for cleanliness
  155
• 1.2 Assembly overview - turbocharger
  156
• 1.3 Removing and installing turbocharger
  160
• 1.4 Checking turbocharger vacuum unit
  167
• 1.5 Removing and installing turbocharger vacuum unit
  168
• 1.6 Adjusting turbocharger vacuum unit
  169
• 2 Charge air system
  172
• 2.1 Assembly overview - charge air cooling
  172
• 2.2 Schematic diagram of turbocharging system
  173
• 2.3 Checking charge air system for leaks
  173
• Mixture preparation - injection
  176
• 1 Injection system
  176
• 1.1 General notes on injection
  176
• 1.2 Rules for cleanliness
  177
• 1.3 Technical data
  177
• 1.4 Assembly overview - intake manifold
  178
• 1.5 Assembly overview - fuel rail
  179
• 1.6 Assembly overview - air filter/engine cover
  180
• 1.7 Removing and dismantling air filter/engine cover
  180
• 1.8 Removing and installing throttle valve module J338
  181
• 1.9 Removing and installing intake manifold
  182
• 1.10 Removing and installing fuel pressure sender G247
  185
• 1.11 Removing and installing injectors
  187
• 1.12 Renewing Teflon seal on injector
  188
• 2 Checking components
  191
• 2.1 Checking double non-return valve
  191
• 3 Engine control unit
  192
• 3.1 Removing and installing engine control unit
  192
• 3.2 Removing and installing anti-theft engine control unit
  192
• Exhaust system
  196
• 1 Removing and installing parts of exhaust system
  196
• 1.1 Assembly overview - exhaust system
  196
• 1.2 Separating middle and rear silencers
  198
• 1.3 Removing and installing front exhaust pipe with catalytic converter
  199
• 1.4 Aligning exhaust system stress free
  201
• Ignition system
  202
• 1 Repairing ignition system
  202
• 1.1 General notes on ignition system
  202
• 1.2 Assembly overview - ignition system
  203
• 1.3 Removing and installing ignition coils with output stage
  203
• 1.4 Spark plug test data
  204