4-cylinder direct injection engine (1.2 l engine, 4V, EA 211, 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
  1
• 1.4 Safety precautions when working on the cooling system
  2
• 1.5 Safety precautions when working on ignition system
  2
• 2 Identification
  3
• 2.1 Engine number/engine data
  3
• 3 Repair notes
  5
• 3.1 Rules for cleanliness
  5
• 3.2 General information
  5
• 3.3 General repair instructions
  6
• 3.4 Foreign objects in engine
  6
• 3.5 Contact corrosion
  6
• 3.6 Routing and attachment of lines
  6
• 3.7 Fitting radiator and condensers
  6
• 3.8 Checking vacuum system
  6
• Removing and installing engine
  8
• 1 Removing and installing engine
  8
• 1.1 Removing engine
  8
• 1.2 Separating engine and gearbox
  37
• 1.3 Securing engine on engine and gearbox support
  39
• 1.4 Installing engine
  40
• 2 Assembly mountings
  44
• 2.1 Assembly overview - assembly mountings
  44
• 2.2 Removing and installing engine mounting
  52
• 2.3 Removing and installing gearbox mountings
  56
• 2.4 Removing and installing pendulum support
  60
• 2.5 Supporting engine in installation position
  63
• 2.6 Adjusting assembly mountings
  80
• 2.7 Checking adjustment of assembly mountings (engine and gearbox mountings)
  82
• Crankshaft group
  84
• 1 Cylinder block (pulley end)
  84
• 1.1 Assembly overview - poly V-belt drive
  84
• 1.2 Removing and installing poly-V belt
  88
• 1.3 Removing and installing tensioner for poly V-belt
  90
• 1.4 Removing and installing vibration damper
  91
• 1.5 Removing and installing engine support
  92
• 1.6 Renewing crankshaft oil seal - belt pulley end
  95
• 2 Cylinder block, gearbox end
  98
• 2.1 Assembly overview - cylinder block, gearbox end
  98
• 2.2 Removing and installing flywheel
  99
• 2.3 Removing and installing sealing flange on gearbox side
  100
• 3 Crankshaft
  109
• 3.1 Crankshaft dimensions
  109
• 3.2 Measuring axial clearance of crankshaft
  109
• 3.3 Renewing needle bearing in crankshaft
  110
• 4 Pistons and conrods
  113
• 4.1 Assembly overview - pistons and conrods
  113
• 4.2 Removing and installing pistons
  115
• 4.3 Checking pistons and cylinder bores
  116
• 4.4 Separating new conrod
  117
• 4.5 Checking radial clearance of conrods
  118
• 4.6 Removing and installing oil spray jets
  118
• 4.7 Setting piston to TDC position
  119
• Cylinder head, valve gear
  123
• 1 Cylinder head
  123
• 1.1 Assembly overview - cylinder head
  123
• 1.2 Assembly overview - camshaft housing
  125
• 1.3 Removing and installing cylinder head
  126
• 1.4 Removing and installing camshaft housing
  131
• 1.5 Checking compression
  133
• 2 Toothed belt drive
  136
• 2.1 Assembly overview - toothed belt cover
  136
• 2.2 Assembly overview - toothed belt
  137
• 2.3 Removing and installing toothed belt guard
  139
• 2.4 Preassembling and installing valve timing tool
  139
• 2.5 Removing and installing toothed belt
  148
• 2.6 Checking valve timing
  154
• 2.7 Adjusting valve timing
  156
• 2.8 Removing toothed belt from camshaft
  165
• 3 Valve gear
  169
• 3.1 Assembly overview - valve gear
  169
• 3.2 Measuring axial play of camshaft
  171
• 3.3 Removing and installing camshaft adjuster
  172
• 3.4 Removing and installing toothed belt pulley
  176
• 3.5 Removing and installing camshaft oil seal
  178
• 3.6 Removing and installing camshaft control valve 1 N205
  185
• 3.7 Removing and installing valve stem seals
  185
• 4 Inlet and exhaust valves
  194
• 4.1 Checking valve guides
  194
• 4.2 Checking valves
  194
• 4.3 Valve dimensions
  195
• Lubrication
  196
• 1 Sump, oil pump
  196
• 1.1 Assembly overview - sump/oil pump
  196
• 1.2 Engine oil:
  200
• 1.3 Removing and installing sump
  201
• 1.4 Removing and installing oil pump
  206
• 1.5 Removing and installing oil level and oil temperature sender G266
  209
• 2 Engine oil cooler
  210
• 2.1 Assembly overview - engine oil cooler
  210
• 2.2 Removing and installing engine oil cooler
  210
• 3 Crankcase ventilation
  212
• 3.1 Assembly overview - crankcase breather system
  212
• 3.2 Removing and installing oil separator
  213
• 4 Oil filter, oil pressure switch
  216
• 4.1 Assembly overview - oil filter/oil pressure switch
  216
• 4.2 Removing and installing oil pressure switch for reduced oil pressure F378
  217
• 4.3 Checking oil pressure and oil pressure switch
  218
• 4.4 Removing and installing oil filter housing
  219
• Cooling
  221
• 1 Cooling system/coolant
  221
• 1.1 Connection diagram - coolant hoses
  221
• 1.2 Checking cooling system for leaks
  225
• 1.3 Draining and adding coolant
  227
• 2 Coolant pump, regulation of cooling system
  235
• 2.1 Assembly overview - coolant pump, thermostat
  235
• 2.2 Assembly overview - electric coolant pump
  238
• 2.3 Assembly overview - coolant temperature sender
  240
• 2.4 Removing and installing electric coolant pump
  241
• 2.5 Removing and installing coolant pump
  243
• 2.6 Removing and installing thermostat
  248
• 2.7 Removing and installing toothed belt pulley for coolant pump
  250
• 2.8 Removing and installing coolant temperature sender G62
  251
• 2.9 Removing and installing radiator outlet coolant temperature sender G83
  252
• 2.10 Removing and installing radiator fan thermal switch F18
  252
• 3 Coolant pipes
  254
• 3.1 Assembly overview - coolant pipes
  254
• 3.2 Removing and installing coolant pipes
  254
• 4 Radiator, radiator fan
  258
• 4.1 Assembly overview - radiator/radiator fan
  258
• 4.2 Assembly overview - radiator cowl and radiator fan
  265
• 4.3 Removing and installing radiator
  268
• 4.4 Removing and installing water radiator for charge air cooling circuit
  276
• 4.5 Removing and installing radiator cowl
  285
• 4.6 Removing and installing radiator fan V7
  290
• Turbocharging/supercharging
  293
• 1 Turbocharger
  293
• 1.1 Assembly overview - turbocharger
  293
• 1.2 Removing and installing turbocharger
  295
• 1.3 Removing and installing charge pressure positioner V465
  298
• 1.4 Removing and installing connection for turbocharger
  299
• 2 Charge air system
  302
• 2.1 Assembly overview - charge air system
  302
• 2.2 Removing and installing charge air cooler
  304
• 2.3 Removing and installing charge pressure sender GX26
  306
• 2.4 Checking charge air system for leaks
  306
• 2.5 Removing and installing air pipe
  308
• Mixture preparation - injection
  311
• 1 Injection system
  311
• 1.1 Overview of fitting locations - injection system
  311
• 2 Air filter
  320
• 2.1 Assembly overview - air filter housing
  320
• 2.2 Removing and installing air filter housing
  323
• 2.3 Removing and installing resonator for intake air
  324
• 3 Intake manifold
  325
• 3.1 Assembly overview - intake manifold
  325
• 3.2 Removing and installing intake manifold
  327
• 3.3 Removing and installing throttle valve module GX3
  329
• 3.4 Cleaning throttle valve module GX3
  330
• 4 Injectors
  331
• 4.1 Assembly overview - fuel rail with injectors
  331
• 4.2 Removing and installing fuel rail
  332
• 4.3 Removing and installing injectors
  333
• 4.4 Cleaning injectors
  343
• 5 Senders and sensors
  346
• 5.1 Removing and installing intake manifold sender GX9
  346
• 5.2 Removing and installing fuel pressure sender G247
  346
• 5.3 Checking fuel pressure sender G247
  347
• 6 High-pressure pump
  350
• 6.1 Assembly overview - high-pressure pump
  350
• 6.2 Removing and installing high-pressure pump
  352
• 6.3 Removing and installing high-pressure pipe
  353
• 7 Lambda probe
  356
• 7.1 Assembly overview - Lambda probe
  356
• 7.2 Removing and installing Lambda probe
  357
• 8 Engine control unit
  360
• 8.1 Removing and installing engine control unit J623
  360
• 8.2 Assembly overview - engine control unit
  371
• Exhaust system
  373
• 1 Exhaust pipes and silencers
  373
• 1.1 Assembly overview - silencers
  373
• 1.2 Separating exhaust pipes from silencers
  383
• 1.3 Removing and installing silencer
  389
• 1.4 Aligning exhaust system free of stress
  395
• 1.5 Checking exhaust system for leaks
  395
• 1.6 Installation position of clamp
  396
• 2 Emission control
  397
• 2.1 Assembly overview - emission control
  397
• 2.2 Removing and installing catalytic converter
  400
• Ignition system
  408
• 1 Ignition system
  408
• 1.1 Assembly overview - ignition system
  408
• 1.2 Removing and installing ignition coils with output stage
  409
• 1.3 Removing and installing knock sensor 1 G61
  411
• 1.4 Removing and installing Hall sender
  411
• 1.5 Removing and installing engine speed sender G28
  412