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

Chapter overview

• Technical data
  1
• 1 Engine number
  1
• 2 Engine data
  2
• Removing and installing engine
  3
• 1 Removing and installing engine
  3
• 1.1 Removing engine
  3
• 1.2 Securing engine to assembly stand
  9
• 1.3 Installing engine
  10
• 1.4 Assembly mountings
  12
• Crankshaft group
  13
• 1 Dismantling and assembling engine
  13
• 1.1 Assembly overview
  14
• 1.2 Removing and installing poly-V-belt
  18
• 2 Sealing flange and flywheel or drive plate
  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
• 2.6 Removing and installing drive plate
  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
  49
• 1.5 Checking compression
  58
• 2 Valve gear
  60
• 2.1 Assembly overview - valve gear
  61
• 2.2 Valve dimensions
  62
• 2.3 Checking valve guides
  62
• 2.4 Renewing valve stem oil seals
  63
• 2.5 Renewing exhaust camshaft oil seal
  67
• 2.6 Removing and installing camshaft adjuster
  69
• 2.7 Removing and installing inlet camshaft control valve 1 N205
  73
• 2.8 Removing and installing camshafts
  74
• Lubrication
  78
• 1 Parts of lubrication system
  78
• 1.1 Engine oil
  78
• 1.2 Assembly overview - parts of lubrication system
  79
• 1.3 Draining oil filter housing
  83
• 1.4 Removing and installing sump
  84
• 1.5 Removing and installing oil pump with balancer shaft gear assembly
  86
• 1.6 Removing and installing oil filter bracket
  90
• 1.7 Checking oil pressure and oil pressure switch
  91
• Cooling
  93
• 1 Parts of cooling system
  93
• 1.1 Assembly overview - parts of cooling system - engine side
  94
• 1.2 Assembly overview - recirculating pump V55 , engine codes AXX, BWA
  95
• 1.3 Assembly overview - recirculating pump V55 , engine code BPY
  96
• 1.4 Assembly overview - parts of cooling system - body side
  97
• 1.5 Coolant hose schematic diagram, engine codes AXX, BWA
  98
• 1.6 Coolant hose schematic diagram, engine code BPY
  99
• 1.7 Bypass thermostat
  100
• 1.8 Draining and filling coolant
  101
• 1.9 Removing and installing coolant pump
  104
• 1.10 Removing and installing coolant pipes
  105
• 1.11 Removing and installing thermostat housing with thermostat
  107
• 1.12 Removing and installing radiator fan V7 and radiator fan 2 V177
  107
• 1.13 Removing and installing radiator
  109
• 1.14 Checking cooling system for leaks
  110
• Fuel supply system
  112
• 1 Safety precautions
  112
• 1.1 Safety precautions when working on fuel supply system
  112
• 1.2 Releasing fuel pressure in high-pressure section
  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 codes AXX, BWA
  117
• 2.4 Emptying fuel tank
  118
• 2.5 Removing and installing fuel tank
  120
• 3 Repairing fuel supply system
  124
• 3.1 Removing and installing fuel delivery unit
  124
• 3.2 Removing and installing fuel gauge sender G
  127
• 3.3 Checking fuel pump
  128
• 3.4 Assembly overview - high-pressure pump
  136
• 3.5 Removing and installing high-pressure pump
  136
• 4 Electronic power control (EPC)
  138
• 4.1 Function of EPC system
  138
• 4.2 Assembly overview - accelerator pedal module
  139
• 4.3 Removing and installing accelerator module
  139
• 5 Activated charcoal filter system, engine code BPY
  141
• 5.1 Function
  141
• 5.2 Schematic diagram of activated charcoal filter system
  142
• 5.3 Assembly overview - activated charcoal filter system
  143
• 5.4 Checking fuel system for leaks
  143
• 6 Activated charcoal filter system, engine codes AXX, BWA
  147
• 6.1 Function
  147
• 6.2 Assembly overview - activated charcoal filter system
  148
• 6.3 Checking fuel tank breather
  148
• Turbocharging/supercharging
  150
• 1 Turbocharger
  150
• 1.1 Installing hose connections with connector couplings
  150
• 1.2 Rules for cleanliness
  151
• 1.3 Assembly overview - turbocharger
  151
• 1.4 Removing and installing turbocharger
  155
• 1.5 Checking turbocharger vacuum unit
  161
• 1.6 Removing and installing turbocharger vacuum unit
  163
• 1.7 Adjusting turbocharger vacuum unit
  164
• 2 Charge air system
  167
• 2.1 Assembly overview - charge air cooling
  167
• 2.2 Schematic diagram of turbocharging system
  168
• 2.3 Checking charge air system for leaks
  168
• Mixture preparation - injection
  171
• 1 Injection system
  171
• 1.1 General notes on injection
  171
• 1.2 Rules for cleanliness
  172
• 1.3 Technical data
  172
• 1.4 Assembly overview - intake manifold
  173
• 1.5 Assembly overview - fuel rail
  174
• 1.6 Assembly overview - engine cover/air filter
  175
• 1.7 Removing and installing engine cover/air filter
  175
• 1.8 Removing and installing air filter element
  176
• 1.9 Removing and installing throttle valve module J338
  177
• 1.10 Removing and installing intake manifold
  177
• 1.11 Removing and installing fuel rail
  180
• 1.12 Removing and installing fuel pressure sender G247
  180
• 1.13 Removing and installing injectors
  182
• 1.14 Renewing Teflon seal on injector
  183
• 2 Checking components
  186
• 3 Engine control unit
  187
• 3.1 Removing and installing engine control unit
  187
• 3.2 Removing and installing anti-theft engine control unit
  188
• Exhaust system
  192
• 1 Removing and installing parts of exhaust system
  192
• 1.1 Assembly overview - exhaust system
  192
• 1.2 Separating centre and rear silencers
  194
• 1.3 Removing and installing front exhaust pipe with catalytic converter
  195
• Ignition system
  198
• 1 Repairing ignition system
  198
• 1.1 General notes on ignition system
  198
• 1.2 Safety precautions
  198
• 1.3 Assembly overview - ignition system
  199
• 1.4 Removing and installing ignition coils with output stages
  199
• 1.5 Test data, spark plugs
  200