4-cylinder direct injection engine (1.4 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
  5
• 3.4 Foreign objects in engine
  7
• 3.5 Contact corrosion
  7
• 3.6 Routing and attachment of lines
  7
• 3.7 Fitting radiator and condensers
  7
• 3.8 Checking vacuum system
  7
• Removing and installing engine
  9
• 1 Removing and installing motor
  9
• 1.1 Removing motor
  9
• 1.2 Separating engine and gearbox
  60
• 1.3 Securing engine on engine and gearbox support
  61
• 1.4 Installing engine
  63
• 2 Assembly mountings
  68
• 2.1 Assembly overview - assembly mountings
  68
• 2.2 Removing and installing engine mounting
  80
• 2.3 Removing and installing gearbox mountings
  85
• 2.4 Removing and installing pendulum support
  87
• 2.5 Supporting engine in installation position
  89
• 2.6 Checking adjustment of assembly mountings (engine and gearbox mountings)
  117
• 2.7 Adjusting assembly mountings
  118
• Crankshaft group
  122
• 1 Cylinder block (pulley end)
  122
• 1.1 Assembly overview - poly V-belt drive
  122
• 1.2 Assembly overview - sealing flange, belt pulley end
  126
• 1.3 Removing and installing poly-V belt
  129
• 1.4 Removing and installing tensioner for poly V-belt
  133
• 1.5 Removing and installing vibration damper
  134
• 1.6 Removing and installing engine support
  136
• 1.7 Renewing crankshaft oil seal - belt pulley end
  139
• 1.8 Removing and installing sealing flange on pulley end
  142
• 2 Cylinder block, gearbox end
  146
• 2.1 Assembly overview - cylinder block, gearbox end
  146
• 2.2 Removing and installing flywheel
  147
• 2.3 Removing and installing sealing flange on gearbox side
  148
• 3 Crankshaft
  160
• 3.1 Renewing needle bearing in crankshaft
  160
• 3.2 Crankshaft dimensions
  163
• 3.3 Measuring axial clearance of crankshaft
  163
• 4 Pistons and conrods
  165
• 4.1 Assembly overview - pistons and conrods
  165
• 4.2 Removing and installing pistons
  168
• 4.3 Removing and installing oil spray jets
  169
• 4.4 Checking pistons and cylinder bores
  170
• 4.5 Checking radial clearance of conrods
  173
• 4.6 Separating new conrod
  173
• 4.7 Setting piston to TDC position
  174
• Cylinder head, valve gear
  179
• 1 Cylinder head
  179
• 1.1 Assembly overview - cylinder head
  179
• 1.2 Assembly overview - camshaft housing
  181
• 1.3 Removing and installing cylinder head
  185
• 1.4 Removing and installing camshaft housing
  190
• 1.5 Checking compression
  196
• 2 Toothed belt drive
  198
• 2.1 Assembly overview - toothed belt cover
  198
• 2.2 Assembly overview - toothed belt
  199
• 2.3 Removing and installing toothed belt guard
  203
• 2.4 Preassembling and installing valve timing tool
  205
• 2.5 Checking valve timing
  213
• 2.6 Adjusting valve timing
  216
• 2.7 Removing and installing toothed belt
  227
• 2.8 Removing toothed belt from camshaft
  234
• 3 Valve gear
  242
• 3.1 Assembly overview - valve gear
  242
• 3.2 Removing and installing camshaft oil seal
  244
• 3.3 Removing and installing camshaft adjuster
  256
• 3.4 Removing and installing toothed belt pulley
  277
• 3.5 Removing and installing camshaft control valve 1 N205
  282
• 3.6 Removing and installing exhaust camshaft control valve 1 N318
  283
• 3.7 Removing and installing valve stem seals
  284
• 4 Inlet and exhaust valves
  296
• 4.1 Checking valve guides
  296
• 4.2 Checking valves
  297
• 4.3 Valve dimensions
  297
• Lubrication
  298
• 1 Sump, oil pump
  298
• 1.1 Assembly overview - sump/oil pump
  298
• 1.2 Engine oil:
  302
• 1.3 Removing and installing lower part of sump
  302
• 1.4 Removing and installing upper part of sump
  308
• 1.5 Removing and installing oil pump
  312
• 1.6 Removing and installing oil level and oil temperature sender G266
  314
• 2 Engine oil cooler
  315
• 2.1 Assembly overview - engine oil cooler
  315
• 2.2 Removing and installing engine oil cooler
  315
• 3 Crankcase ventilation
  317
• 3.1 Assembly overview - crankcase breather system
  317
• 3.2 Removing and installing oil separator
  318
• 4 Oil filter, oil pressure switch
  322
• 4.1 Assembly overview - oil filter/oil pressure switch
  322
• 4.2 Removing and installing oil pressure switch F1
  324
• 4.3 Removing and installing oil pressure switch for reduced oil pressure F378
  325
• 4.4 Checking oil pressure
  326
• 4.5 Removing and installing oil pressure regulating valve N428
  328
• Cooling
  330
• 1 Cooling system/coolant
  330
• 1.1 Connection diagram - coolant hoses
  330
• 1.2 Checking cooling system for leaks
  332
• 1.3 Draining and adding coolant
  340
• 2 Coolant pump, regulation of cooling system
  348
• 2.1 Assembly overview - coolant pump, thermostat
  348
• 2.2 Assembly overview - electric coolant pump
  351
• 2.3 Assembly overview - coolant temperature sender
  352
• 2.4 Removing and installing electric coolant pump
  354
• 2.5 Removing and installing coolant pump
  356
• 2.6 Removing and installing thermostat
  362
• 2.7 Removing and installing toothed belt pulley for coolant pump
  366
• 2.8 Removing and installing coolant temperature sender G62
  367
• 2.9 Removing and installing radiator outlet coolant temperature sender G83
  370
• 3 Coolant pipes
  374
• 3.1 Assembly overview - coolant pipes
  374
• 3.2 Removing and installing coolant pipes
  374
• 4 Radiator, radiator fan
  379
• 4.1 Assembly overview - radiator/radiator fan
  379
• 4.2 Assembly overview - radiator cowl and radiator fan
  388
• 4.3 Removing and installing radiator
  392
• 4.4 Removing and installing water radiator for charge air cooling circuit
  399
• 4.5 Removing and installing radiator cowl
  407
• 4.6 Removing and installing radiator fan V7
  413
• Turbocharging/supercharging
  416
• 1 Turbocharger
  416
• 1.1 Assembly overview - turbocharger
  416
• 1.2 Removing and installing turbocharger
  420
• 1.3 Removing and installing charge pressure positioner V465
  426
• 1.4 Removing and installing connection for turbocharger
  429
• 2 Charge air system
  433
• 2.1 Assembly overview - charge air system
  433
• 2.2 Removing and installing charge air cooler
  435
• 2.3 Removing and installing charge pressure sender GX26
  438
• 2.4 Checking charge air system for leaks
  439
• 2.5 Removing and installing air pipe
  441
• Mixture preparation - injection
  444
• 1 Injection system
  444
• 1.1 Overview of fitting locations - injection system
  444
• 2 Injectors
  449
• 2.1 Assembly overview - fuel rail with injectors
  449
• 2.2 Removing and installing fuel rail
  453
• 2.3 Removing and installing injectors
  454
• 2.4 Cleaning injectors
  468
• 3 Air filter
  470
• 3.1 Assembly overview - air filter housing
  470
• 3.2 Removing and installing air filter housing
  472
• 3.3 Removing and installing air guide on lock carrier
  474
• 3.4 Removing and installing resonator for intake air
  476
• 4 Intake manifold
  478
• 4.1 Assembly overview - intake manifold
  478
• 4.2 Removing and installing intake manifold
  481
• 4.3 Removing and installing throttle valve module GX3
  484
• 4.4 Cleaning throttle valve module GX3
  485
• 5 Senders and sensors
  487
• 5.1 Removing and installing intake manifold sender GX9
  487
• 5.2 Removing and installing fuel pressure sender G247
  487
• 5.3 Checking fuel pressure sender G247
  489
• 5.4 Removing and installing exhaust gas pressure sensor 1 G450
  493
• 6 Engine control unit
  495
• 6.1 Assembly overview - engine control unit J623
  495
• 6.2 Removing and installing engine control unit J623
  496
• 6.3 Removing and installing engine (motor) control unit J623 with protective housing
  502
• 7 High-pressure pump
  519
• 7.1 Assembly overview - high-pressure pump
  519
• 7.2 Removing and installing high-pressure pump
  525
• 7.3 Removing and installing high-pressure pipe
  527
• 8 Lambda probe
  530
• 8.1 Assembly overview - Lambda probe
  530
• 8.2 Removing and installing Lambda probe
  531
• Exhaust system
  536
• 1 Exhaust pipes and silencers
  536
• 1.1 Assembly overview - silencers
  536
• 1.2 Separating exhaust pipes from silencers
  546
• 1.3 Removing and installing silencer
  550
• 1.4 Installation position of clamp
  559
• 1.5 Aligning exhaust system free of stress
  560
• 1.6 Checking exhaust system for leaks
  567
• 2 Emission control
  568
• 2.1 Assembly overview - emission control
  568
• 2.2 Removing and installing catalytic converter
  570
• 2.3 Removing and installing particulate filter
  577
• Ignition system
  578
• 1 Ignition system
  578
• 1.1 Assembly overview - ignition system
  578
• 1.2 Removing and installing ignition coils with output stage
  580
• 1.3 Removing and installing knock sensor 1 G61
  583
• 1.4 Removing and installing Hall sender
  584
• 1.5 Removing and installing engine speed sender G28
  585