4-cylinder injection engine (1.4 l direct injection engine, turbocharger and supercharger)

Kapitelübersicht

• Technical data
  1
• 1 Safety instructions
  1
• 1.1 Safety precautions when working on fuel supply system
  1
• 1.3 Safety precautions when working on ignition system
  2
• 1.4 Safety precautions when working on cooling system
  3
• 2 Identification
  4
• 2.1 Engine number, engine data
  4
• 3 Repair instructions
  6
• 3.1 Rules for cleanliness
  6
• 3.2 Foreign objects in engine
  6
• 3.3 Contact corrosion
  6
• 3.4 Routing and securing lines
  6
• 3.5 Installing coolers, condensers and radiators
  6
• Removing and installing engine
  8
• 1 Removing and installing engine
  8
• 1.1 Removing engine
  8
• 1.2 Separating engine and gearbox
  16
• 1.3 Securing engine on engine and gearbox support
  17
• 1.4 Installing engine
  19
• 2 Assembly mountings
  22
• 2.1 Assembly overview - assembly mountings
  22
• 2.2 Removing and installing engine mountings
  24
• 2.3 Supporting engine in installation position
  29
• 2.4 Adjusting assembly mountings
  35
• 2.5 Checking adjustment of assembly mountings (engine and gearbox mountings)
  37
• 3 Engine cover panel
  38
• 3.1 Removing and installing engine cover panel
  38
• Crankshaft group
  39
• 1 Cylinder block (pulley end)
  39
• 1.1 Assembly overview - poly V-belt drive
  39
• 1.2 Assembly overview - cylinder block (pulley end)
  42
• 1.3 Removing and installing poly V-belt
  44
• 1.4 Removing and installing vibration damper
  45
• 1.5 Removing and installing ancillary bracket
  49
• 1.6 Renewing crankshaft oil seal - belt pulley end
  50
• 2 Cylinder block, gearbox end
  54
• 2.1 Assembly overview - cylinder block, gearbox end
  54
• 2.2 Removing and installing sealing flange on gearbox side
  55
• 3 Crankshaft
  65
• 3.1 Assembly overview - crankshaft
  65
• 3.2 Crankshaft dimensions
  66
• 3.3 Renewing needle bearing in crankshaft
  66
• 4 Pistons and conrods
  69
• 4.1 Assembly overview - pistons and conrods
  69
• 4.2 Checking piston and cylinder bore
  71
• 4.3 Separating new conrod
  72
• 4.4 Removing and installing pistons
  73
• 4.5 Removing and installing oil spray jets
  74
• Cylinder head, valve gear
  76
• 1 Cylinder head
  76
• 1.1 Assembly overview - cylinder head
  76
• 1.2 Removing and installing cylinder head
  78
• 1.3 Removing and installing camshaft housing
  79
• 1.4 Checking compression
  85
• 2 Cover for timing chain
  88
• 2.1 Removing and installing valve timing housing
  88
• 3 Chain drive
  91
• 3.1 Removing and installing timing chain and chain drive for oil pump
  91
• 3.2 Checking timing chain
  98
• 3.3 Checking valve timing
  106
• 3.4 Adjusting valve timing
  109
• 4 Valve gear
  117
• 4.1 Assembly overview - valve gear
  117
• 4.2 Measuring axial play of camshaft
  118
• 4.3 Removing and installing valve stem seals
  119
• 5 Inlet and exhaust valves
  122
• 5.1 Reworking valve seats
  122
• 5.2 Checking valve guides
  123
• Lubrication
  125
• 1 Sump, oil pump
  125
• 1.1 Assembly overview - sump and oil pump
  125
• 1.2 Engine oil
  126
• 1.3 Removing and installing sump
  127
• 1.4 Removing and installing oil pump
  131
• 2 Oil filter, oil pressure switch
  134
• 2.1 Checking oil pressure and oil pressure switch
  134
• Cooling
  136
• 1 Cooling system, coolant
  136
• 1.1 Coolant hose schematic diagram
  136
• 1.2 Checking cooling system for leaks
  136
• 1.3 Draining and filling coolant
  138
• 2 Coolant pump, regulation of cooling system
  144
• 2.1 Assembly overview - thermostat
  144
• 2.2 Removing and installing coolant circulation pump V50
  145
• 2.3 Removing and installing coolant pump
  146
• 2.4 Removing and installing coolant pump pulley
  151
• 3 Radiator and radiator fan
  156
• 3.1 Assembly overview - radiator and radiator fan
  156
• 3.2 Removing and installing radiator
  158
• 3.3 Removing and installing radiator cowling
  159
• 3.4 Removing and installing radiator fan V7 and radiator fan 2 V177
  159
• Turbocharging/supercharging
  161
• 1 Turbocharger
  161
• 1.1 Assembly overview - turbocharger
  161
• 1.2 Assembly overview - turbocharger air recirculation valve N249
  163
• 1.3 Removing and installing turbocharger
  163
• 1.4 Checking vacuum unit for turbocharger
  168
• 1.5 Adjusting vacuum unit for turbocharger
  169
• 1.6 Renewing vacuum unit for turbocharger
  174
• 2 Charge air system
  176
• 2.1 Assembly overview - charge air system
  176
• 2.2 Assembly overview - charge-air hose connections
  177
• 2.3 Removing and installing charge air cooler
  178
• 2.4 Checking charge air system for leaks
  180
• 3 Supercharger
  183
• 3.1 Assembly overview - supercharger
  183
• 3.2 Removing and installing supercharger
  184
• 3.3 Removing and installing supercharger input shaft seal
  191
• Mixture preparation - injection
  195
• 1 Injection system
  195
• 1.1 Releasing high pressure in fuel system
  195
• 2 Injectors
  196
• 2.1 Assembly overview - fuel rail with injectors
  196
• 2.2 Removing and installing injectors
  196
• 2.3 Renewing seals on injectors
  199
• 3 Air filter
  203
• 3.1 Assembly overview - air filter housing
  203
• 3.2 Removing and installing air filter housing
  204
• 4 Intake manifold
  205
• 4.1 Assembly overview - intake manifold
  205
• 4.2 Assembly overview - lower part of intake manifold with fuel rail
  207
• 4.3 Removing and installing lower part of intake manifold
  209
• 4.4 Removing and installing lower part of intake manifold with fuel rail
  209
• 4.5 Removing and installing throttle valve module J338
  210
• 4.6 Cleaning throttle valve module J338
  212
• 5 Senders and sensors
  214
• 5.1 Checking fuel pressure sender G247
  214
• 6 Engine control unit
  217
• 6.1 Removing and installing engine control unit J623 without protective housing
  217
• 6.2 Removing and installing engine control unit J623 with protective housing
  219
• 7 High-pressure pump
  222
• 7.1 Assembly overview - high-pressure pump
  222
• 7.2 Removing and installing high-pressure pump
  223
• Exhaust system
  227
• 1 Exhaust pipes, silencers
  227
• 1.1 Assembly overview - silencers
  227
• 1.2 Removing and installing front exhaust pipe
  228
• 1.3 Separating exhaust pipes, silencers
  230
• 1.4 Aligning exhaust system free of stress
  231
• 2 Emission control
  233
• 2.1 Assembly overview - emission control
  233
• Ignition system
  235
• 1 Ignition system
  235
• 1.1 Assembly overview - ignition system
  235
• 1.2 Test data, spark plugs
  236
• 1.3 Removing and installing ignition coils with output stage
  236
• 1.4 Removing and installing engine speed sender G28
  238