4-cyl. direct injection engine (1.5 l, 4V, EA211 EVO, turbocharger)

Kapitelübersicht

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety regulations for working on fuel supply
  1
• 1.2 Safety measures when working on vehicles with start/stop system
  2
• 1.4 Safety precautions when working on the cooling system
  2
• 1.5 Safety precautions when working on ignition system
  2
• 1.6 Safety precautions when working on exhaust system
  3
• 2 Identification
  4
• 2.1 Engine number/engine data
  4
• 3 Repair instructions
  7
• 3.1 Rules for cleanliness
  7
• 3.2 General information
  7
• 3.3 Foreign objects in engine
  7
• 3.4 Contact corrosion
  8
• 3.5 Routing and attachment of lines
  8
• 3.6 Checking vacuum system
  8
• Removing and installing engine
  10
• 1 Removing and installing engine
  10
• 1.1 Removing engine
  10
• 1.2 Separating engine and gearbox
  18
• 1.3 Securing engine on engine and gearbox support
  22
• 1.4 Installing engine
  23
• 2 Assembly mountings
  27
• 2.1 Assembly overview – assembly mountings
  27
• 2.2 Removing and installing engine mounting
  29
• 2.3 Removing and installing gearbox mounting
  30
• 2.4 Removing and installing pendulum support
  31
• 2.5 Supporting engine in installation position
  32
• 2.6 Adjusting assembly mountings
  37
• 2.7 Checking adjustment of assembly mountings
  39
• 3 Engine cover panel
  40
• 3.1 Removing and installing engine cover
  40
• Crankshaft group
  41
• 1 Cylinder block (pulley end)
  41
• 1.1 Assembly overview - cylinder block (pulley end)
  41
• 1.2 Assembly overview - sealing flange, belt pulley end
  43
• 1.3 Removing and installing poly-V belt
  43
• 1.4 Removing and installing tensioner for poly V-belt
  44
• 1.5 Removing and installing vibration damper
  45
• 1.6 Removing and installing engine support
  46
• 1.7 Renewing crankshaft oil seal - belt pulley end
  48
• 1.8 Removing and installing sealing flange on pulley end
  51
• 2 Cylinder block, gearbox end
  52
• 2.1 Assembly overview - cylinder block, gearbox end
  52
• 2.2 Removing and installing flywheel
  54
• 2.3 Removing and installing sealing flange on gearbox side
  56
• 2.4 Removing and installing adapter plate
  67
• 2.5 Removing and installing intermediate plate
  68
• 3 Crankshaft
  69
• 3.1 Renewing needle bearing in crankshaft
  69
• 3.2 Crankshaft dimensions
  71
• 3.3 Measuring axial clearance of crankshaft
  71
• 4 Pistons and conrods
  74
• 4.1 Assembly overview - pistons and conrods
  74
• 4.2 Removing and installing pistons
  77
• 4.3 Checking pistons and cylinder bores
  79
• 4.4 Separating new conrod
  82
• 4.5 Checking radial clearance of conrods
  82
• 4.6 Removing and installing oil spray jets
  83
• 4.7 Setting piston to TDC position
  84
• Cylinder head, valve gear
  87
• 1 Cylinder head
  87
• 1.1 Assembly overview - cylinder head
  87
• 1.2 Assembly overview - camshaft housing
  88
• 1.3 Removing and installing cylinder head
  91
• 1.4 Removing and installing camshaft housing
  95
• 1.5 Checking compression
  98
• 2 Toothed belt drive
  101
• 2.1 Assembly overview - toothed belt cover
  101
• 2.2 Assembly overview - toothed belt
  101
• 2.3 Removing and installing toothed belt guard
  103
• 2.4 Removing and installing toothed belt
  105
• 2.5 Checking valve timing
  108
• 2.6 Preassembling and installing valve timing tool
  111
• 2.7 Adjusting valve timing
  120
• 2.8 Removing toothed belt from camshaft
  130
• 3 Valve gear
  133
• 3.1 Assembly overview - valve gear
  133
• 3.2 Removing and installing camshaft oil seal
  135
• 3.3 Removing and installing camshaft adjuster
  142
• 3.4 Removing and installing cam actuator N583/N587/N591/N595
  150
• 3.5 Removing and installing exhaust camshaft control valve 1 N318
  152
• 3.6 Removing and installing valve stem seals
  153
• 3.7 Removing and installing holder for oil seal
  159
• 3.8 Checking control valve
  162
• 3.9 Removing and installing oil seal on holder
  162
• 3.10 Removing and installing inlet camshaft control valve 1 N727
  164
• 4 Inlet and exhaust valves
  166
• 4.1 Checking valve guides
  166
• 4.2 Checking valves
  167
• 4.3 Valve dimensions
  167
• Lubrication
  168
• 1 Sump, oil pump
  168
• 1.1 Assembly overview - sump/oil pump
  168
• 1.2 Engine oil:
  171
• 1.3 Removing and installing oil sump
  171
• 1.4 Removing and installing oil pump
  173
• 1.5 Removing and installing oil level and oil temperature sender G266
  175
• 2 Engine oil cooler
  177
• 2.1 Assembly overview - engine oil cooler
  177
• 2.2 Removing and installing engine oil cooler
  177
• 3 Crankcase ventilation
  179
• 3.1 Assembly overview - crankcase breather system
  179
• 3.2 Removing and installing oil separator
  180
• 4 Oil filter, oil pressure switch
  184
• 4.1 Assembly overview - oil pressure switches/oil pressure control
  184
• 4.2 Removing and installing oil pressure sender G10
  184
• 4.3 Checking oil pressure and oil pressure switch
  186
• 4.4 Removing and installing oil pressure regulating valve N428
  186
• 5 Oil circuit
  188
• 5.1 Assembly overview - oil circuit
  188
• 5.2 Removing and installing oil supply line
  190
• 5.3 Removing and installing oil return line for turbocharger
  191
• Cooling
  193
• 1 Cooling system/coolant
  193
• 1.1 Connection diagram - coolant hoses
  193
• 1.2 Checking cooling system for leaks
  195
• 1.3 Draining and adding coolant
  197
• 2 Coolant pump, regulation of cooling system
  205
• 2.1 Assembly overview - coolant pump, thermostat
  205
• 2.2 Assembly overview - electric coolant pump
  206
• 2.3 Assembly overview - coolant temperature sender
  207
• 2.4 Removing and installing charge air cooling pump V188
  208
• 2.5 Checking coolant pump
  210
• 2.6 Removing and installing coolant pump
  212
• 2.7 Removing and installing toothed belt for coolant pump
  216
• 2.8 Removing and installing toothed belt pulley for coolant pump
  216
• 2.9 Removing and installing coolant temperature sender G62
  219
• 2.10 Removing and installing engine outlet coolant temperature sender G82
  220
• 2.11 Removing and installing radiator outlet coolant temperature sender G83
  221
• 2.12 Removing and installing engine temperature regulation module GX33
  223
• 3 Coolant pipes
  226
• 3.1 Assembly overview - coolant pipes
  226
• 3.2 Removing and installing coolant pipes
  227
• 4 Radiator, radiator fan
  238
• 4.1 Assembly overview - radiator, radiator fan
  238
• 4.2 Assembly overview – radiator cowl and radiator fan
  240
• 4.3 Removing and installing radiator
  240
• 4.4 Removing and installing cooler for charge air cooling circuit
  242
• 4.5 Removing and installing radiator cowl
  244
• 4.6 Removing and installing radiator fan VX57
  245
• 4.7 Removing and installing radiator fan 2 V177
  246
• Turbocharging/supercharging
  248
• 1 Turbocharger
  248
• 1.1 Assembly overview - turbocharger
  248
• 1.2 Removing and installing turbocharger
  250
• 1.3 Removing and installing connection for turbocharger
  254
• 1.4 Removing and installing charge pressure control module GX34
  255
• 2 Charge air system
  257
• 2.1 Assembly overview - charge air system
  257
• 2.2 Checking charge air cooler for leaks
  259
• 2.3 Removing and installing charge air cooler
  264
• 2.4 Removing and installing charge pressure sender GX26
  266
• 2.5 Checking charge air system for leaks
  267
• 2.6 Removing and installing air intake pipe
  270
• Mixture preparation - injection
  271
• 1 Injectors
  271
• 1.1 Assembly overview - fuel rail with injectors
  271
• 1.2 Removing and installing fuel rail
  272
• 1.3 Removing and installing injectors
  274
• 1.4 Cleaning injectors
  278
• 2 Air filter
  281
• 2.1 Assembly overview - air filter housing
  281
• 2.2 Removing and installing air filter housing
  283
• 2.3 Removing and installing air guide on lock carrier
  283
• 3 Intake manifold
  285
• 3.1 Assembly overview – intake manifold
  285
• 3.2 Removing and installing intake manifold
  287
• 3.3 Cleaning throttle valve module GX3
  290
• 3.4 Removing and installing throttle valve module GX3
  290
• 3.5 Removing and installing intake connecting pipe
  292
• 4 Senders and sensors
  294
• 4.1 Removing and installing fuel pressure sender G247
  294
• 4.2 Checking fuel pressure sender G247
  295
• 4.3 Removing and installing intake manifold sender GX9
  296
• 4.4 Removing and installing exhaust gas pressure sensor 1 G450
  297
• 4.5 Removing and installing air mass measurement module GX35
  299
• 5 Engine control unit
  300
• 5.1 Removing and installing engine control unit J623
  300
• 6 High-pressure pump
  301
• 6.1 Assembly overview - high-pressure pump
  301
• 6.2 Removing and installing high-pressure pump
  302
• 6.3 Removing and installing high-pressure pipe
  303
• 7 Lambda probe
  305
• 7.1 Assembly overview - Lambda probe
  305
• 7.2 Removing and installing Lambda probe 1 before catalytic converter GX10
  305
• 7.3 Removing and installing Lambda probe 1 after catalytic converter GX7
  307
• Exhaust system
  310
• 1 Exhaust pipes and silencers
  310
• 1.1 Assembly overview – silencers
  310
• 1.2 Separating exhaust pipes from silencers
  312
• 1.3 Removing and installing front silencer
  313
• 1.4 Removing and installing centre silencer
  314
• 1.5 Removing and installing rear silencer
  315
• 1.6 Aligning exhaust system free of stress
  316
• 1.7 Checking exhaust system for leaks
  317
• 1.8 Installation position of clamp
  318
• 2 Emission control
  319
• 2.1 Assembly overview – emission control
  319
• 2.2 Removing and installing catalytic converter
  321
• 2.3 Removing and installing particulate filter
  324
• Ignition system
  325
• 1 Ignition system
  325
• 1.1 Assembly overview - ignition system
  325
• 1.2 Removing and installing ignition coils
  327
• 1.3 Removing and installing knock sensor 1 G61
  329
• 1.4 Removing and installing engine speed sender G28
  330
• 1.5 Removing and installing inlet camshaft position sender G1002
  331
• 1.6 Removing and installing exhaust camshaft position sender G1003
  332