3-cyl. injection engine (1.0 l, natural gas 4V, EA 211)

Kapitelübersicht

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety regulations for working on fuel supply
  1
• 1.2 Safety precautions when working on natural gas system
  1
• 1.3 Safety measures when working on vehicles with a start/stop system
  3
• 1.5 Safety precautions when working on the cooling system
  4
• 1.6 Safety precautions when working on ignition system
  4
• 2 Identification
  5
• 2.1 Engine number/engine data
  5
• 3 Repair notes
  7
• 3.1 Rules for cleanliness
  7
• 3.2 Foreign objects in engine
  7
• 3.3 Contact corrosion
  7
• 3.4 Routing and attachment of lines
  7
• 3.5 Fitting radiator and condensers
  8
• Removing and installing engine
  9
• 1 Removing and installing engine
  9
• 1.1 Removing engine
  9
• 1.2 Separating engine and gearbox
  18
• 1.3 Securing engine on engine and gearbox support
  20
• 1.4 Installing engine
  21
• 2 Assembly mountings
  24
• 2.1 Assembly overview - assembly mountings
  24
• 2.2 Removing and installing engine mounting
  26
• 2.3 Removing and installing gearbox mounting
  27
• 2.4 Removing and installing pendulum support
  28
• 2.5 Supporting engine in installation position
  29
• 2.6 Adjusting assembly mountings
  39
• 2.7 Checking adjustment of assembly mountings
  40
• Crankshaft group
  41
• 1 Cylinder block (pulley end)
  41
• 1.1 Assembly overview - poly V-belt drive
  41
• 1.2 Assembly overview - cylinder block (pulley end)
  41
• 1.3 Removing and installing poly-V belt
  43
• 1.4 Renewing crankshaft oil seal - belt pulley end
  46
• 2 Cylinder block, gearbox end
  49
• 2.1 Assembly overview - cylinder block, gearbox end
  49
• 2.2 Removing and installing flywheel
  50
• 2.3 Removing and installing sealing flange on gearbox side
  51
• 3 Crankshaft
  63
• 3.1 Crankshaft dimensions
  63
• 4 Pistons and conrods
  64
• 4.1 Assembly overview - pistons and conrods
  64
• 4.2 Checking pistons and cylinder bores
  66
• 4.3 Separating new conrod
  68
• 4.4 Setting piston to TDC position
  69
• Cylinder head, valve gear
  72
• 1 Cylinder head
  72
• 1.1 Assembly overview - cylinder head
  72
• 1.2 Removing and installing cylinder head
  75
• 1.3 Removing and installing camshaft housing
  84
• 1.4 Checking compression
  89
• 2 Toothed belt drive
  93
• 2.1 Assembly overview - toothed belt cover
  93
• 2.2 Assembly overview - toothed belt
  93
• 2.3 Removing and installing toothed belt
  95
• 2.4 Preassembling and installing valve timing tool
  106
• 2.5 Checking valve timing
  114
• 2.6 Adjusting valve timing
  118
• 2.7 Removing toothed belt from camshaft
  129
• 3 Valve gear
  135
• 3.1 Assembly overview - valve gear
  135
• 3.2 Measuring axial play of camshaft
  136
• 3.3 Removing and installing camshaft adjuster
  137
• 3.4 Removing and installing toothed belt pulley
  143
• 3.5 Removing and installing camshaft oil seal
  147
• 3.6 Removing and installing valve stem seals
  157
• 4 Inlet and exhaust valves
  168
• 4.1 Checking valve guides
  168
• Lubrication
  169
• 1 Sump, oil pump
  169
• 1.1 Assembly overview - sump/oil pump
  169
• 1.2 Engine oil:
  173
• 1.3 Removing and installing sump
  173
• 1.4 Removing and installing oil pump
  178
• 2 Crankcase ventilation
  181
• 2.1 Assembly overview - crankcase breather system
  181
• 2.2 Removing and installing oil separator
  182
• 3 Oil filter, oil pressure switch
  187
• 3.1 Removing and installing oil pressure switch F1
  187
• 3.2 Checking oil pressure and oil pressure switch
  188
• 3.3 Removing and installing oil filter housing
  190
• Cooling
  192
• 1 Cooling system/coolant
  192
• 1.1 Connection diagram - coolant hoses
  192
• 1.2 Checking cooling system for leaks
  192
• 1.3 Draining and adding coolant
  196
• 2 Coolant pump, regulation of cooling system
  202
• 2.1 Assembly overview - coolant pump
  202
• 2.2 Assembly overview - thermostat
  205
• 2.3 Removing and installing coolant pump
  208
• 2.4 Removing and installing thermostat
  213
• 2.5 Removing and installing toothed belt for coolant pump
  220
• 2.6 Removing and installing coolant temperature sender G62
  222
• 2.7 Removing and installing radiator fan thermal switch F18
  224
• 3 Radiator, radiator fan
  226
• 3.1 Assembly overview - radiator, radiator fan
  226
• 3.2 Removing and installing radiator
  228
• 3.3 Removing and installing radiator cowl with radiator fan
  232
• 3.4 Removing and installing radiator fan V7
  234
• Mixture preparation - injection
  238
• 1 Injection system
  238
• 1.1 Overview of fitting locations - injection system
  238
• 1.2 Assembly overview - fuel system
  241
• 2 Injectors
  244
• 2.1 Assembly overview - fuel rail with injectors
  244
• 2.2 Removing and installing injectors
  244
• 2.3 Checking injectors
  248
• 2.4 Cleaning injectors
  253
• 3 Checking natural gas supply system for leaks
  257
• 3.1 Distinguishing between pressure sections of natural gas supply system
  257
• 3.2 Determining pressure in gas system
  261
• 3.3 Determining operating mode of natural gas vehicles
  261
• 3.4 Activating and deactivating natural gas mode
  261
• 3.5 Checking gas system for leaks
  263
• 4 Gas injectors
  268
• 4.1 Assembly overview - gas rail
  268
• 4.2 Removing and installing gas rail with gas injector N366/N367/N368
  270
• 4.3 Removing and installing gas rail sensor G401
  274
• 5 Air filter
  276
• 5.1 Assembly overview - air filter housing
  276
• 5.2 Removing and installing air filter housing
  277
• 6 Intake manifold
  279
• 6.1 Assembly overview – intake manifold
  279
• 6.2 Removing and installing intake manifold
  281
• 6.3 Removing and installing throttle valve module GX3
  287
• 6.4 Cleaning throttle valve module GX3
  289
• 7 Senders and sensors
  291
• 7.1 Removing and installing intake manifold sender GX9
  291
• 8 Engine control unit
  293
• 8.1 Assembly overview – motor control unit
  293
• 8.2 Removing and installing engine control unit J623
  293
• 8.3 Removing and installing engine (motor) control unit J623 with protective housing
  295
• 9 Lambda probe
  297
• 9.1 Assembly overview - Lambda probe
  297
• 9.2 Removing and installing Lambda probe
  302
• 10 Gas pressure regulator
  307
• 10.1 Assembly overview - gas pressure regulator
  307
• 10.2 Removing and installing gas pressure regulator
  309
• 10.3 Removing and installing tank pressure sensor G400
  312
• Exhaust system
  316
• 1 Exhaust pipes and silencers
  316
• 1.1 Assembly overview – silencers
  316
• 1.2 Separating exhaust pipes from silencers
  317
• 1.3 Removing and installing silencer
  318
• 1.4 Checking exhaust system for leaks
  320
• 1.5 Installation position of clamp
  320
• 2 Emission control
  323
• 2.1 Assembly overview – emission control
  323
• 2.2 Removing and installing catalytic converter
  328
• Ignition system
  333
• 1 Ignition system
  333
• 1.1 Assembly overview - ignition system
  333
• 1.2 Removing and installing ignition coils with output stage
  335
• 1.3 Removing and installing knock sensor 1 G61
  339
• 1.4 Removing and installing Hall sender
  339
• 1.5 Removing and installing engine speed sender G28
  341