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
• 1.6 Safety precautions when working on exhaust system
  3
• 2 Identification
  4
• 2.1 Engine number/engine data
  4
• 3 Repair notes
  6
• 3.1 Rules for cleanliness
  6
• 3.2 General information
  6
• 3.3 General repair instructions
  6
• 3.4 Foreign objects in engine
  8
• 3.5 Contact corrosion
  8
• 3.6 Routing and attachment of lines
  8
• 3.7 Fitting radiator and condensers
  8
• 3.8 Checking vacuum system
  8
• 3.9 Identification labels
  9
• 3.10 Using impact drivers
  9
• 3.11 Nuts and bolts
  10
• 3.12 Bleeding fuel system
  10
• 3.13 Checking fuel system for leaks
  10
• Removing and installing engine
  11
• 1 Removing and installing engine
  11
• 1.1 Removing engine
  11
• 1.2 Separating engine and gearbox
  25
• 1.3 Securing engine on engine and gearbox support
  26
• 1.4 Installing engine
  28
• 2 Assembly mountings
  32
• 2.1 Assembly overview - assembly mountings
  32
• 2.2 Removing and installing engine mounting
  35
• 2.3 Removing and installing gearbox mounting
  36
• 2.4 Removing and installing pendulum support
  38
• 2.5 Supporting engine in installation position
  38
• 2.6 Adjusting assembly mountings
  43
• 2.7 Checking adjustment of assembly mountings
  46
• Crankshaft group
  48
• 1 Cylinder block (pulley end)
  48
• 1.1 Assembly overview - poly V-belt drive
  48
• 1.2 Assembly overview - sealing flange, belt pulley end
  52
• 1.3 Removing and installing poly-V belt
  55
• 1.4 Removing and installing tensioner for poly V-belt
  59
• 1.5 Removing and installing vibration damper
  60
• 1.6 Removing and installing engine support
  62
• 1.7 Renewing crankshaft oil seal - belt pulley end
  65
• 1.8 Removing and installing sealing flange on pulley end
  68
• 2 Cylinder block, gearbox end
  72
• 2.1 Assembly overview - flywheel
  72
• 2.2 Assembly overview - drive plate
  73
• 2.3 Removing and installing flywheel
  75
• 2.4 Removing and installing drive plate
  76
• 2.5 Removing and installing sealing flange on gearbox side
  78
• 3 Crankshaft
  91
• 3.1 Renewing needle bearing in crankshaft
  91
• 3.2 Crankshaft dimensions
  93
• 3.3 Measuring axial clearance of crankshaft
  94
• 4 Pistons and conrods
  96
• 4.1 Assembly overview - pistons and conrods
  96
• 4.2 Removing and installing pistons
  100
• 4.3 Removing and installing oil spray jets
  101
• 4.4 Checking pistons and cylinder bores
  103
• 4.5 Checking radial clearance of conrods
  106
• 4.6 Separating new conrod
  106
• 4.7 Setting piston to TDC position
  107
• Cylinder head, valve gear
  113
• 1 Cylinder head
  113
• 1.1 Assembly overview - cylinder head
  113
• 1.2 Assembly overview - camshaft housing
  115
• 1.3 Removing and installing cylinder head
  120
• 1.4 Removing and installing camshaft housing
  125
• 1.5 Checking compression
  130
• 2 Toothed belt drive
  132
• 2.1 Assembly overview - toothed belt cover
  132
• 2.2 Assembly overview - toothed belt
  132
• 2.3 Removing and installing toothed belt guard
  134
• 2.4 Removing and installing toothed belt
  135
• 2.5 Preassembling and installing valve timing tool
  140
• 2.6 Checking valve timing
  151
• 2.7 Adjusting valve timing
  153
• 2.8 Removing toothed belt from camshaft
  165
• 3 Valve gear
  170
• 3.1 Assembly overview - valve gear
  170
• 3.2 Measuring axial play of camshaft
  172
• 3.3 Removing and installing camshaft oil seal
  173
• 3.4 Removing and installing camshaft adjuster
  182
• 3.5 Removing and installing camshaft control valve 1 N205
  192
• 3.6 Removing and installing exhaust camshaft control valve 1 N318
  193
• 3.7 Removing and installing valve stem oil seals
  194
• 3.8 Removing and installing cam actuators
  204
• 4 Inlet and exhaust valves
  206
• 4.1 Checking valve guides
  206
• 4.2 Checking valves
  207
• 4.3 Valve dimensions
  207
• Lubrication
  208
• 1 Sump, oil pump
  208
• 1.1 Assembly overview - sump/oil pump
  208
• 1.2 Engine oil:
  212
• 1.3 Removing and installing lower part of sump
  212
• 1.4 Removing and installing upper part of sump
  218
• 1.5 Removing and installing oil pump
  223
• 1.6 Removing and installing oil level and oil temperature sender G266
  225
• 2 Engine oil cooler
  226
• 2.1 Assembly overview - engine oil cooler
  226
• 2.2 Removing and installing engine oil cooler
  226
• 3 Crankcase ventilation
  228
• 3.1 Assembly overview - crankcase breather system
  228
• 3.2 Removing and installing oil separator
  229
• 4 Oil filter, oil pressure switch
  232
• 4.1 Assembly overview - oil filter/oil pressure switch
  232
• 4.2 Removing and installing oil pressure switch F1
  234
• 4.3 Removing and installing oil pressure switch for reduced oil pressure F378
  236
• 4.4 Removing and installing oil pressure regulating valve N428
  238
• 4.5 Checking oil pressure
  239
• Cooling
  242
• 1 Cooling system/coolant
  242
• 1.1 Connection diagram - coolant hoses
  242
• 1.2 Assembly overview – coolant expansion tank
  243
• 1.3 Checking cooling system for leaks
  244
• 1.4 Draining and adding coolant
  248
• 1.5 Removing and installing coolant expansion tank
  256
• 2 Coolant pump, regulation of cooling system
  258
• 2.1 Assembly overview - coolant pump, thermostat
  258
• 2.2 Assembly overview - electric coolant pump
  261
• 2.3 Assembly overview - engine preheater
  262
• 2.4 Assembly overview - coolant temperature sender
  263
• 2.5 Removing and installing electric coolant pump
  264
• 2.6 Removing and installing coolant pump
  266
• 2.7 Removing and installing thermostat
  272
• 2.8 Removing and installing toothed belt pulley for coolant pump
  276
• 2.9 Removing and installing coolant temperature sender G62
  281
• 2.10 Removing and installing radiator outlet coolant temperature sender G83
  283
• 2.11 Removing and installing engine preheating element Z97
  284
• 3 Coolant pipes
  287
• 3.1 Assembly overview - coolant pipes
  287
• 3.2 Removing and installing coolant pipes
  288
• 4 Radiator, radiator fan
  295
• 4.1 Assembly overview - radiator/radiator fan
  295
• 4.2 Assembly overview – radiator cowl and radiator fan
  297
• 4.3 Removing and installing radiator
  299
• 4.4 Removing and installing water radiator for charge air cooling circuit
  303
• 4.5 Removing and installing radiator cowl with radiator fan
  304
• 4.6 Removing and installing radiator fan
  306
• Turbocharging/supercharging
  308
• 1 Turbocharger
  308
• 1.1 Assembly overview - turbocharger
  308
• 1.2 Removing and installing turbocharger
  313
• 1.3 Removing and installing charge pressure positioner V465
  319
• 1.4 Removing and installing connection for turbocharger
  322
• 2 Charge air system
  325
• 2.1 Assembly overview - charge air system
  325
• 2.2 Removing and installing charge pressure sender GX26
  327
• 2.3 Removing and installing charge air cooler
  328
• 2.4 Checking charge air system for leaks
  331
• 2.5 Removing and installing air intake pipe
  333
• Mixture preparation - injection
  335
• 1 Injection system
  335
• 1.1 Overview of fitting locations - injection system
  335
• 2 Injectors
  342
• 2.1 Assembly overview - fuel rail with injectors
  342
• 2.2 Removing and installing fuel rail
  344
• 2.3 Removing and installing injectors
  345
• 2.4 Cleaning injectors
  351
• 3 Air filter
  353
• 3.1 Assembly overview - air filter housing
  353
• 3.2 Removing and installing air filter housing
  355
• 3.3 Removing and installing air guide on lock carrier
  356
• 3.4 Removing and installing resonator for intake air
  357
• 4 Intake manifold
  359
• 4.1 Assembly overview – intake manifold
  359
• 4.2 Removing and installing intake manifold
  362
• 4.3 Removing and installing throttle valve module GX3
  368
• 4.4 Cleaning throttle valve module GX3
  369
• 4.5 Removing and installing activated charcoal filter solenoid valve 1 N80
  370
• 5 Senders and sensors
  372
• 5.1 Removing and installing intake manifold sender GX9
  372
• 5.2 Removing and installing fuel pressure sender G247
  372
• 5.3 Checking fuel pressure sender G247
  374
• 6 Engine control unit
  379
• 6.1 Assembly overview – engine/motor control unit
  379
• 6.2 Removing and installing engine control unit J623
  379
• 7 High-pressure pump
  387
• 7.1 Assembly overview - high-pressure pump
  387
• 7.2 Removing and installing high-pressure pump
  392
• 7.3 Removing and installing high-pressure pipe
  394
• 8 Lambda probe
  396
• 8.1 Assembly overview - Lambda probe
  396
• 8.2 Removing and installing Lambda probe
  397
• Exhaust system
  401
• 1 Exhaust pipes and silencers
  401
• 1.1 Assembly overview – silencer
  401
• 1.2 Removing and installing silencer
  405
• 1.3 Separating exhaust pipes from silencers
  408
• 1.4 Aligning exhaust system free of stress
  410
• 1.5 Checking exhaust system for leaks
  411
• 1.6 Installation position of clamp
  411
• 2 Emission control
  414
• 2.1 Assembly overview – emission control
  414
• 2.2 Removing and installing catalytic converter
  418
• 2.3 Removing and installing particulate filter
  426
• 2.4 Removing and installing exhaust flap control unit J883
  426
• Ignition system
  427
• 1 Ignition system
  427
• 1.1 Assembly overview - ignition system
  427
• 1.2 Removing and installing ignition coils with output stage
  429
• 1.3 Removing and installing knock sensor 1 G61
  432
• 1.4 Removing and installing Hall sender
  432
• 1.5 Removing and installing engine speed sender G28
  433