4-cylinder direct injection engine (1.5 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 a 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 instructions
  7
• 3.1 Rules for cleanliness
  7
• 3.2 General information
  7
• 3.3 General repair instructions
  8
• 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
• Removing and installing engine
  10
• 1 Removing and installing engine
  10
• 1.1 Removing engine
  10
• 1.2 Separating engine and gearbox
  20
• 1.3 Securing engine on engine and gearbox support
  23
• 1.4 Installing engine
  24
• 2 Assembly mountings
  29
• 2.1 Assembly overview – assembly mountings
  29
• 2.2 Removing and installing engine mounting
  41
• 2.3 Removing and installing gearbox mounting
  42
• 2.4 Removing and installing pendulum support
  44
• 2.5 Supporting engine in installation position
  45
• 2.6 Adjusting assembly mountings
  78
• 2.7 Checking adjustment of assembly mountings
  80
• 3 Engine cover panel
  82
• 3.1 Removing and installing engine cover
  82
• Crankshaft group
  83
• 1 Cylinder block (pulley end)
  83
• 1.1 Assembly overview - poly V-belt drive
  83
• 1.2 Removing and installing poly-V belt
  89
• 1.3 Removing and installing tensioner for poly V-belt
  94
• 1.4 Removing and installing vibration damper
  96
• 1.5 Removing and installing engine support
  99
• 1.6 Renewing crankshaft oil seal - belt pulley end
  101
• 2 Cylinder block, gearbox end
  105
• 2.1 Assembly overview - cylinder block, gearbox end
  105
• 2.2 Removing and installing flywheel
  108
• 2.3 Removing and installing sealing flange on gearbox side
  110
• 3 Crankshaft
  123
• 3.1 Renewing needle bearing in crankshaft
  123
• 3.2 Crankshaft dimensions
  125
• 3.3 Measuring axial clearance of crankshaft
  125
• 4 Pistons and conrods
  127
• 4.1 Assembly overview - pistons and conrods
  127
• 4.2 Removing and installing pistons
  129
• 4.3 Checking pistons and cylinder bores
  131
• 4.4 Separating new conrod
  133
• 4.5 Checking radial clearance of conrods
  133
• 4.6 Removing and installing oil spray jets
  134
• 4.7 Setting piston to TDC position
  135
• Cylinder head, valve gear
  138
• 1 Cylinder head
  138
• 1.1 Assembly overview - cylinder head
  138
• 1.2 Assembly overview - camshaft housing
  140
• 1.3 Removing and installing cylinder head
  143
• 1.4 Removing and installing camshaft housing
  147
• 1.5 Checking compression
  153
• 2 Toothed belt drive
  156
• 2.1 Assembly overview - toothed belt cover
  156
• 2.2 Assembly overview - toothed belt
  157
• 2.3 Assembly overview - valve timing tool
  160
• 2.4 Removing and installing toothed belt guard
  160
• 2.5 Removing and installing toothed belt
  161
• 2.6 Preassembling and installing valve timing tool
  168
• 2.7 Checking valve timing
  178
• 2.8 Adjusting valve timing
  181
• 2.9 Removing toothed belt from camshaft
  192
• 3 Valve gear
  197
• 3.1 Assembly overview - valve gear
  197
• 3.2 Removing and installing camshaft oil seal
  200
• 3.3 Removing and installing camshaft adjuster
  212
• 3.4 Removing and installing cam actuators
  224
• 3.5 Removing and installing inlet camshaft control valve 1 N727
  226
• 3.6 Removing and installing exhaust camshaft control valve 1 N318
  227
• 3.7 Removing and installing valve stem seals
  228
• 3.8 Removing and installing holder for oil seal
  243
• 4 Inlet and exhaust valves
  247
• 4.1 Checking valve guides
  247
• 4.2 Checking valves
  248
• 4.3 Valve dimensions
  248
• Lubrication
  249
• 1 Sump, oil pump
  249
• 1.1 Assembly overview - sump/oil pump
  249
• 1.2 Engine oil:
  254
• 1.3 Removing and installing sump
  254
• 1.4 Removing and installing oil pump
  259
• 1.5 Removing and installing oil level and oil temperature sender G266
  262
• 2 Engine oil cooler
  263
• 2.1 Assembly overview - engine oil cooler
  263
• 2.2 Removing and installing engine oil cooler
  263
• 3 Crankcase ventilation
  265
• 3.1 Assembly overview - crankcase breather system
  265
• 3.2 Removing and installing oil separator
  267
• 4 Oil filter, oil pressure switch
  271
• 4.1 Assembly overview - oil pressure switches/oil pressure control
  271
• 4.2 Removing and installing oil pressure sender G10
  271
• 4.3 Checking oil pressure and oil pressure switch
  273
• 4.4 Removing and installing oil filter housing
  273
• 4.5 Removing and installing oil pressure regulating valve N428
  274
• Cooling
  276
• 1 Cooling system/coolant
  276
• 1.1 Connection diagram - coolant hoses
  276
• 1.2 Checking cooling system for leaks
  278
• 1.3 Draining and adding coolant
  282
• 1.4 Flushing cooling system
  290
• 2 Coolant pump, regulation of cooling system
  305
• 2.1 Assembly overview - coolant pump, thermostat
  305
• 2.2 Assembly overview - electric coolant pump
  307
• 2.3 Assembly overview - coolant temperature sender
  307
• 2.4 Removing and installing electric coolant pump
  308
• 2.5 Removing and installing coolant pump
  311
• 2.6 Removing and installing toothed belt pulley for coolant pump
  316
• 2.7 Removing and installing coolant temperature sender G62
  320
• 2.8 Removing and installing radiator outlet coolant temperature sender G83
  322
• 2.9 Removing and installing engine outlet coolant temperature sender G82
  324
• 2.10 Removing and installing engine temperature regulation module GX33
  326
• 2.11 Checking coolant pump
  330
• 3 Coolant pipes
  336
• 3.1 Assembly overview - coolant pipes
  336
• 3.2 Removing and installing coolant pipes
  338
• 4 Radiator, radiator fan
  347
• 4.1 Assembly overview - radiator/radiator fan
  347
• 4.2 Assembly overview – radiator cowl and radiator fan
  349
• 4.3 Assembly overview - radiator blind
  351
• 4.4 Removing and installing radiator
  354
• 4.5 Removing and installing water radiator for charge air cooling circuit
  357
• 4.6 Removing and installing radiator cowl
  362
• 4.7 Removing and installing radiator fan
  363
• 4.8 Removing and installing radiator blind
  365
• 4.9 Removing and installing radiator blind control motor V544
  367
• Turbocharging/supercharging
  373
• 1 Turbocharger
  373
• 1.1 Assembly overview - turbocharger
  373
• 1.2 Removing and installing turbocharger
  379
• 1.3 Removing and installing connection for turbocharger
  384
• 1.4 Removing and installing charge pressure control module GX34
  386
• 2 Charge air system
  391
• 2.1 Assembly overview - charge air system
  391
• 2.2 Removing and installing charge air cooler
  394
• 2.3 Removing and installing charge pressure sender GX26
  397
• 2.4 Checking charge air system for leaks
  398
• 2.5 Removing and installing air pipe
  402
• 2.6 Checking charge air cooler for leaks
  409
• Mixture preparation - injection
  415
• 1 Injection system
  415
• 1.1 Overview of fitting locations - injection system
  415
• 2 Air filter
  425
• 2.1 Assembly overview - air filter housing
  425
• 2.2 Removing and installing air filter housing
  427
• 2.3 Removing and installing air guide on lock carrier
  429
• 3 Intake manifold
  433
• 3.1 Assembly overview – intake manifold
  433
• 3.2 Removing and installing intake manifold
  436
• 3.3 Removing and installing throttle valve module GX3
  442
• 3.4 Cleaning throttle valve module GX3
  444
• 4 Injectors
  446
• 4.1 Assembly overview - fuel rail with injectors
  446
• 4.2 Removing and installing fuel rail
  448
• 4.3 Removing and installing injectors
  449
• 4.4 Cleaning injectors
  457
• 5 Senders and sensors
  459
• 5.1 Removing and installing intake manifold sender GX9
  459
• 5.2 Removing and installing fuel pressure sender G247
  460
• 5.3 Checking fuel pressure sender G247
  462
• 5.4 Removing and installing exhaust gas pressure sensor 1 G450
  466
• 5.5 Removing and installing air mass measurement module GX35
  467
• 6 High-pressure pump
  469
• 6.1 Assembly overview - high-pressure pump
  469
• 6.2 Removing and installing high-pressure pump
  470
• 6.3 Removing and installing high-pressure pipe
  472
• 7 Lambda probe
  474
• 7.1 Assembly overview - Lambda probe
  474
• 7.2 Removing and installing Lambda probe
  475
• 8 Engine control unit
  477
• 8.1 Removing and installing engine control unit J623
  477
• Exhaust system
  485
• 1 Exhaust pipes and silencers
  485
• 1.1 Assembly overview – silencers
  485
• 1.2 Removing and installing silencer
  501
• 1.3 Separating exhaust pipes from silencers
  516
• 1.4 Aligning exhaust system free of stress
  518
• 1.5 Checking exhaust system for leaks
  518
• 1.6 Installation position of clamp
  519
• 1.7 Assembly overview - front exhaust pipe
  520
• 1.8 Removing and installing bracket for front exhaust pipe
  521
• 2 Emission control
  523
• 2.1 Assembly overview – emission control
  523
• 2.2 Removing and installing catalytic converter
  526
• 2.3 Removing and installing particulate filter
  531
• 2.4 Removing and installing exhaust flap control unit J883
  532
• Ignition system
  533
• 1 Ignition system
  533
• 1.1 Assembly overview - ignition system
  533
• 1.2 Removing and installing ignition coils with output stage
  535
• 1.3 Removing and installing knock sensor 1 G61
  539
• 1.4 Removing and installing engine speed sender G28
  540
• 1.5 Removing and installing inlet camshaft position sender G1002
  542
• 1.6 Removing and installing exhaust camshaft position sender G1003
  543