4-cylinder injection engine (2.0 l turbocharger)

Chapter overview

• Technical data
  1
• 1 Engine number
  1
• 2 Engine data
  2
• Removing and installing engine
  3
• 1 Removing and installing motor
  3
• 1.1 Removing engine
  4
• 1.2 Securing engine to assembly stand
  17
• 1.3 Installing engine
  19
• 1.4 Checking and adjusting assembly mountings
  23
• 1.5 Specified torques for assembly mountings
  26
• Crankshaft group
  29
• 1 Dismantling and assembling engine
  29
• 1.1 Assembly overview
  29
• 1.2 Removing and installing poly-V belt
  37
• 2 Sealing flanges and flywheel
  41
• 2.1 Assembly overview - sealing flange
  41
• 2.2 Renewing crankshaft oil seal - pulley end
  42
• 2.3 Removing and installing sealing flange - pulley end
  46
• 2.4 Removing and installing crankshaft sealing flange - flywheel end
  51
• 2.5 Removing and installing dual-mass flywheel
  52
• 3 Removing and installing crankshaft
  55
• 3.1 Assembly overview - crankshaft
  55
• 3.3 Crankshaft dimensions
  59
• 4 Dismantling and assembling pistons and conrods
  61
• 4.1 Assembly overview - pistons and conrods
  61
• 4.2 Separating new conrod
  63
• 4.3 Checking pistons, piston rings and cylinder bores
  64
• 4.4 Piston and cylinder dimensions
  66
• Cylinder head, valve gear
  67
• 1 Cylinder head
  67
• 1.1 Assembly overview - cylinder head
  67
• 1.2 Removing and installing cylinder head cover
  69
• 1.3 Removing and installing cylinder head
  72
• 1.4 Removing and installing toothed belt, vehicles without split toothed belt guard
  81
• 1.5 Removing and installing toothed belt, vehicles with split toothed belt guard
  93
• 1.6 Checking compression
  105
• 2 Repairing valve gear
  108
• 2.1 Assembly overview - valve gear
  108
• 2.2 Valve dimensions
  110
• 2.3 Checking valve guides
  110
• 2.4 Renewing valve stem seals
  111
• 2.5 Renewing exhaust camshaft seal
  117
• 2.6 Removing and installing camshaft adjuster
  120
• 2.7 Removing and installing camshaft control valve 1 N205
  125
• 2.8 Removing and installing camshafts
  127
• Lubrication
  131
• 1 Parts of lubrication system
  131
• 1.1 Engine oil:
  131
• 1.2 Assembly overview - parts of lubrication system
  132
• 1.3 Drain oiling filter housing
  138
• 1.4 Removing and installing sump
  139
• 1.5 Removing, installing and adjusting balance shaft gear assembly with oil pump
  143
• 1.6 Removing and installing oil filter bracket
  149
• 1.7 Removing and installing oil pressure switch F1
  149
• 1.8 Checking oil pressure and oil pressure switch (single pin oil pressure switch)
  151
• 1.9 Checking oil pressure and oil pressure switch (2-pin oil pressure switch)
  154
• Cooling
  157
• 1 Removing and installing parts of cooling system
  157
• 1.1 Assembly overview - parts of cooling system, engine side
  158
• 1.4 Assembly overview - parts of cooling system, body side
  161
• 1.7 Bypass thermostat
  166
• 1.8 Draining and adding coolant
  166
• 1.9 Removing and installing coolant pump
  172
• 1.10 Removing and installing coolant pipes
  174
• 1.11 Removing and installing coolant distributor housing with thermostat
  176
• 1.12 Removing and installing cowling with radiator fan V7 and radiator fan 2 V177
  177
• 1.13 Removing and installing radiator
  179
• 1.14 Checking cooling system for leaks
  182
• Fuel supply system
  185
• 1 Safety precautions
  185
• 1.1 Safety regulations for working on fuel supply
  185
• 1.2 Reducing pressure in high-pressure section of fuel system
  186
• 2 Rules for cleanliness
  188
• 3 Fuel
  189
• 3.1 Assembly overview - fuel tank (vehicles with engine codes AXX and BWA)
  189
• 3.2 Assembly overview - fuel tank (vehicles with engine code BPY)
  191
• 3.3 Emptying fuel tank
  194
• 3.4 Removing and installing fuel tank
  202
• 3.5 Assembly overview - fuel filter with attachments
  205
• 3.6 Removing and installing fuel filter
  206
• 4 Repairing fuel supply system
  209
• 4.1 Removing and installing fuel delivery unit
  209
• 4.2 Removing and installing fuel gauge sender G
  213
• 4.3 Checking fuel pump G6
  215
• 5 Electronic power control (EPC)
  231
• 5.1 Function of EPC system
  231
• 5.2 Assembly overview - accelerator module
  231
• 5.3 Removing and installing accelerator pedal module
  232
• 6 Activated charcoal filter system (vehicles with engine codes AXX and BWA)
  236
• 6.1 Function
  236
• 6.2 Assembly overview - activated charcoal filter system
  236
• 6.3 Checking fuel tank breather
  237
• 7 Activated charcoal filter system (vehicles with engine code BPY)
  241
• 7.1 Function
  241
• 7.2 Overview of activated charcoal filter system
  242
• 7.3 Assembly overview - activated charcoal filter system
  244
• 7.4 Removing and installing activated charcoal filter
  246
• 7.5 Removing and installing fuel system diagnostic pump V144
  246
• 7.6 Checking fuel system for leaks
  247
• Turbocharging/supercharging
  257
• 1 Turbocharger
  257
• 1.1 General information
  257
• 1.2 Safety precautions
  258
• 1.3 Rules for cleanliness
  259
• 1.4 Assembly overview - turbocharger
  259
• 1.5 Removing and installing turbocharger
  264
• 1.6 Checking vacuum unit for turbocharger
  273
• 1.7 Removing and installing vacuum unit for turbocharger
  274
• 1.8 Adjusting vacuum unit for turbocharger
  275
• 2 Charge air system
  281
• 2.2 Assembly overview - charge air cooling system (vehicles with engine code BPY)
  282
• 2.3 Schematic diagram of turbocharger system
  282
• 2.4 Hose connections with push-on couplings
  283
• 2.5 Removing and installing charge air cooler
  284
• 2.6 Checking charge air system for leaks
  287
• Mixture preparation - injection
  291
• 1 Injection system
  291
• 1.1 General notes on injection
  291
• 1.2 Technical data
  292
• 1.3 Overview of fitting locations
  292
• 1.4 Assembly overview - intake manifold
  300
• 1.5 Assembly overview - fuel rail (vehicles up to 05.2006)
  302
• 1.6 Assembly overview - fuel rail (vehicles from 05.2006)
  303
• 1.7 Assembly overview - air filter/engine cover panel
  305
• 1.8 Removing and installing engine cover panel/air filter
  305
• 1.9 Removing and installing air filter element
  306
• 1.10 Removing and installing throttle valve module J338
  308
• 1.11 Cleaning throttle valve module J338
  310
• 1.12 Removing and installing fuel pressure sender G247
  311
• 1.13 Removing and installing intake manifold
  313
• 1.15 Removing and installing fuel rail
  320
• 1.16 Assembly overview - high-pressure pump
  322
• 1.17 Removing and installing high-pressure pump
  324
• 1.18 Removing and installing injectors
  326
• 1.19 Renewing Teflon seal on injector
  329
• 2 Checking components
  333
• 2.1 Checking double non-return valve
  333
• 2.2 Checking fuel pressure sender G247
  334
• 3 Engine control unit
  338
• 3.1 Reading and erasing engine control unit fault memory
  338
• 3.2 Removing and installing engine control unit, vehicles to 10.2008
  339
• 3.3 Removing and installing engine control unit, vehicles from 11.2008
  344
• Exhaust system
  350
• 1 Removing and installing parts of exhaust system
  350
• 1.1 Assembly overview - exhaust system
  351
• 1.2 Removing and installing front exhaust pipe with catalytic converter
  353
• 1.3 Separating and joining front and rear silencers
  356
• 1.4 Aligning exhaust system free of stress
  358
• Ignition system
  360
• 1 Repairing ignition system
  360
• 1.1 General notes on ignition system
  360
• 1.2 Safety precautions
  360
• 1.3 Assembly overview - ignition system
  360
• 1.4 Removing and installing ignition coils with output stage
  361
• 1.5 Test data, spark plugs
  364