4-cylinder injection engine (1.4 l, natural gas, 4 V EA 211, turbocharger)

Kapitelübersicht

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety regulations for working on fuel supply
  1
• 1.2 Safety precautions when working on vehicles with a gas system
  1
• 1.3 Safety measures when working on vehicles with start/stop system
  3
• 1.5 Safety precautions when working on cooling system
  4
• 1.6 Safety precautions when working on ignition system
  4
• 2 Identification
  5
• 2.1 Engine number/engine data
  5
• 3 Repair notes
  6
• 3.1 Rules for cleanliness
  6
• 3.2 Foreign objects in engine
  6
• 3.3 Contact corrosion
  6
• 3.4 Routing and attachment of lines
  6
• 3.5 Fitting radiator and condensers
  7
• Removing and installing engine
  8
• 1 Removing and installing engine
  8
• 1.1 Removing engine
  8
• 1.2 Separating engine and gearbox
  20
• 1.3 Securing engine on engine and gearbox support
  22
• 1.4 Installing engine
  23
• 2 Assembly mountings
  29
• 2.1 Assembly overview - assembly mountings
  29
• 2.2 Removing and installing engine mounting
  30
• 2.3 Removing and installing gearbox mounting
  35
• 2.4 Removing and installing pendulum support
  38
• 2.5 Checking adjustment of assembly mountings (engine and gearbox mountings)
  39
• 2.6 Adjusting assembly mountings
  39
• Crankshaft group
  46
• 1 Cylinder block (pulley end)
  46
• 1.1 Assembly overview - poly V-belt drive
  46
• 1.2 Assembly overview - sealing flange, belt pulley end
  50
• 1.3 Removing and installing poly-V belt
  51
• 1.4 Removing and installing tensioner for poly V-belt
  54
• 1.5 Removing and installing vibration damper
  55
• 1.6 Removing and installing engine support
  57
• 1.7 Renewing crankshaft oil seal - belt pulley end
  63
• 1.8 Removing and installing sealing flange on pulley end
  66
• 2 Cylinder block, gearbox end
  70
• 2.1 Assembly overview - cylinder block, gearbox end
  70
• 2.2 Removing and installing flywheel
  71
• 2.3 Removing and installing sealing flange on gearbox side
  72
• 3 Crankshaft
  81
• 3.1 Crankshaft dimensions
  81
• 3.2 Measuring axial clearance of crankshaft
  81
• 3.3 Renewing needle bearing in crankshaft
  82
• 4 Pistons and conrods
  85
• 4.1 Assembly overview - pistons and conrods
  85
• 4.2 Removing and installing pistons
  87
• 4.3 Removing and installing oil spray jets
  87
• 4.4 Separating new conrod
  88
• 4.5 Checking pistons and cylinder bores
  89
• 4.6 Checking radial clearance of conrods
  90
• 4.7 Setting piston to TDC position
  90
• Cylinder head, valve gear
  94
• 1 Cylinder head
  94
• 1.1 Assembly overview - cylinder head
  94
• 1.2 Assembly overview - camshaft housing
  96
• 1.3 Removing and installing cylinder head
  97
• 1.4 Removing and installing camshaft housing
  103
• 1.5 Checking compression
  108
• 2 Toothed belt drive
  111
• 2.1 Assembly overview - toothed belt cover
  111
• 2.2 Assembly overview - toothed belt
  112
• 2.3 Removing and installing toothed belt guard
  113
• 2.4 Preassembling and installing valve timing tool
  114
• 2.5 Checking valve timing
  121
• 2.6 Adjusting valve timing
  124
• 2.7 Removing toothed belt from camshaft
  132
• 2.8 Removing and installing toothed belt
  137
• 3 Valve gear
  146
• 3.1 Assembly overview - valve gear
  146
• 3.2 Removing and installing camshaft adjuster
  147
• 3.3 Removing and installing toothed belt pulley
  154
• 3.4 Measuring axial play of camshaft
  158
• 3.5 Removing and installing camshaft oil seal
  159
• 3.6 Removing and installing camshaft control valve 1 N205
  168
• 3.7 Removing and installing valve stem seals
  168
• 4 Inlet and exhaust valves
  176
• 4.1 Checking valve guides
  176
• 4.2 Checking valves
  176
• 4.3 Valve dimensions
  177
• Lubrication
  178
• 1 Sump, oil pump
  178
• 1.1 Assembly overview - sump/oil pump
  178
• 1.2 Engine oil:
  182
• 1.3 Removing and installing oil sump
  183
• 1.4 Removing and installing oil level and oil temperature sender G266
  192
• 1.5 Removing and installing oil pump
  192
• 2 Engine oil cooler
  194
• 2.1 Assembly overview - engine oil cooler
  194
• 2.2 Removing and installing engine oil cooler
  195
• 3 Crankcase ventilation
  197
• 3.1 Assembly overview - crankcase breather system
  197
• 3.2 Removing and installing oil separator
  198
• 4 Oil filter, oil pressure switch
  201
• 4.1 Assembly overview - oil filter/oil pressure switch
  201
• 4.2 Removing and installing oil pressure switch
  202
• 4.3 Removing and installing oil pressure regulating valve N428
  204
• 4.4 Checking oil pressure
  205
• Cooling
  208
• 1 Cooling system/coolant
  208
• 1.1 Connection diagram - coolant hoses
  208
• 1.2 Draining and adding coolant
  209
• 1.3 Checking cooling system for leaks
  214
• 2 Coolant pump, regulation of cooling system
  216
• 2.1 Assembly overview - coolant pump, thermostat
  216
• 2.2 Assembly overview - charge air cooling pump V188
  219
• 2.3 Assembly overview - coolant temperature sender
  220
• 2.4 Removing and installing coolant pump
  221
• 2.5 Removing and installing toothed belt pulley for coolant pump
  224
• 2.6 Removing and installing thermostat
  226
• 2.7 Removing and installing charge air cooling pump V188
  228
• 2.8 Removing and installing coolant temperature sender G62
  230
• 2.9 Removing and installing radiator outlet coolant temperature sender G83
  232
• 3 Coolant pipes
  234
• 3.1 Assembly overview - coolant pipes
  234
• 3.2 Removing and installing coolant pipes
  234
• 4 Radiator, radiator fan
  241
• 4.1 Assembly overview - radiator/radiator fan
  241
• 4.2 Assembly overview - radiator cowl and radiator fan
  243
• 4.3 Removing and installing radiator
  244
• 4.4 Removing and installing radiator cowl
  247
• 4.5 Removing and installing radiator fan V7
  248
• Turbocharging/supercharging
  249
• 1 Exhaust turbocharger
  249
• 1.1 Assembly overview - turbocharger
  249
• 1.2 Removing and installing turbocharger
  251
• 1.3 Removing and installing charge pressure positioner V465
  255
• 1.4 Removing and installing connection for turbocharger
  256
• 2 Charge air system
  259
• 2.1 Assembly overview - charge air system
  259
• 2.2 Removing and installing air intake pipe
  261
• 2.3 Removing and installing charge pressure sender GX26
  262
• 2.4 Removing and installing charge air cooler
  262
• 2.5 Checking charge air system for leaks
  265
• Mixture preparation - injection
  268
• 1 Injection system
  268
• 1.1 Overview of fitting locations - injection system
  268
• 2 Air filter
  272
• 2.1 Assembly overview - air filter housing
  272
• 2.2 Removing and installing air filter housing
  273
• 2.3 Removing and installing resonator for intake air
  274
• 3 Intake manifold
  275
• 3.1 Assembly overview - intake manifold
  275
• 3.2 Removing and installing intake manifold
  277
• 3.3 Removing and installing throttle valve module GX3
  281
• 3.4 Cleaning throttle valve module GX3
  281
• 4 Checking natural gas supply system for leaks
  283
• 4.1 Distinguishing between pressure sections of natural gas supply system
  283
• 4.2 Determining pressure in gas system
  286
• 4.3 Determining operating mode of natural gas vehicles
  286
• 4.4 Activating and deactivating natural gas mode
  286
• 4.5 Checking gas system for leaks
  288
• 5 Gas pressure regulator
  293
• 5.1 Assembly overview - gas pressure regulator
  293
• 5.2 Removing and installing gas pressure regulator
  295
• 5.3 Removing and installing tank pressure sensor G400
  299
• 6 Gas injectors
  302
• 6.1 Assembly overview - gas rail
  302
• 6.3 Removing and installing gas rail temperature and pressure sensor GX21
  306
• 7 Injectors
  309
• 7.1 Assembly overview - fuel rail with injectors
  309
• 7.2 Removing and installing fuel rail
  310
• 7.3 Removing and installing injectors
  312
• 8 Senders and sensors
  319
• 8.1 Removing and installing intake manifold sender GX9
  319
• 8.2 Removing and installing fuel pressure sender G247
  319
• 8.3 Checking fuel pressure sender G247
  321
• 9 High-pressure pump
  325
• 9.1 Assembly overview - high-pressure pump
  325
• 9.2 Removing and installing high-pressure pump
  326
• 9.3 Removing and installing high-pressure pipe
  327
• 10 Lambda probe
  330
• 10.1 Assembly overview - Lambda probe
  330
• 11 Engine (motor) control unit
  333
• 11.1 Removing and installing engine (motor) control unit J623
  333
• Exhaust system
  339
• 1 Exhaust pipes and silencers
  339
• 1.1 Assembly overview - silencers
  339
• 1.2 Removing and installing silencer
  340
• 1.3 Aligning exhaust system free of stress
  341
• 1.4 Check exhaust system for leaks
  341
• 2 Exhaust gas cleaning
  342
• 2.1 Assembly overview - emission control
  342
• 2.2 Removing and installing catalytic converter
  343
• Ignition system
  347
• 1 Ignition system
  347
• 1.1 Assembly overview - ignition system
  347
• 1.2 Removing and installing ignition coils with output stage
  348
• 1.3 Removing and installing knock sensor 1 G61
  350
• 1.4 Removing and installing Hall sender G40
  351
• 1.5 Removing and installing engine speed sender G28
  351