4-cylinder injection engine (1.6 l engine, 4 V, EA 211)

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 ignition system
  2
• 1.5 Safety precautions when working on exhaust system
  2
• 1.6 Safety precautions when working on the 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 General information
  6
• 3.3 General repair notes
  6
• 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 engine
  9
• 1.1 Removing engine
  9
• 1.2 Separating engine and gearbox
  46
• 1.3 Securing engine on engine and gearbox support
  50
• 1.4 Installing engine
  52
• 2 Assembly mountings
  62
• 2.1 Assembly overview – assembly mountings
  62
• 2.2 Supporting engine in installation position
  74
• 2.3 Removing and installing engine mounting
  85
• 2.4 Removing and installing gearbox mounting
  90
• 2.5 Removing and installing pendulum support
  95
• 2.6 Checking adjustment of assembly mountings
  99
• 2.7 Adjusting assembly mountings
  101
• Crankshaft group
  107
• 1 Cylinder block (pulley end)
  107
• 1.1 Assembly overview - poly V-belt drive
  107
• 1.2 Removing and installing poly-V belt
  114
• 1.3 Removing and installing tensioner for poly V-belt
  122
• 1.4 Removing and installing vibration damper
  123
• 1.5 Removing and installing engine support
  125
• 1.6 Renewing crankshaft oil seal - belt pulley end
  132
• 2 Cylinder block, gearbox end
  135
• 2.1 Assembly overview - cylinder block, gearbox end
  135
• 2.2 Removing and installing flywheel
  139
• 2.3 Removing and installing drive plate
  140
• 2.4 Removing and installing sealing flange on gearbox side
  143
• 3 Crankshaft
  155
• 3.1 Measuring axial clearance of crankshaft
  155
• 4 Pistons and conrods
  157
• 4.1 Assembly overview - pistons and conrods
  157
• 4.2 Removing and installing pistons
  161
• 4.3 Checking pistons and cylinder bores
  162
• 4.4 Separating new conrod
  164
• 4.5 Checking radial clearance of conrods
  165
• 4.6 Removing and installing oil spray jets
  166
• 4.7 Setting piston to TDC position
  167
• Cylinder head, valve gear
  170
• 1 Cylinder head
  170
• 1.1 Assembly overview - cylinder head
  170
• 1.2 Assembly overview - camshaft housing
  172
• 1.3 Removing and installing cylinder head
  174
• 1.4 Removing and installing camshaft housing
  178
• 1.5 Checking compression
  181
• 2 Toothed belt drive
  184
• 2.1 Assembly overview - toothed belt cover
  184
• 2.2 Assembly overview - toothed belt
  184
• 2.3 Removing and installing toothed belt guard
  186
• 2.4 Removing and installing toothed belt
  187
• 2.5 Preassembling and installing valve timing tool
  194
• 2.6 Checking valve timing
  203
• 2.7 Adjusting valve timing
  207
• 2.8 Removing toothed belt from camshaft
  218
• 3 Valve gear
  224
• 3.1 Assembly overview - valve gear
  224
• 3.2 Removing and installing camshaft adjuster
  226
• 3.3 Removing and installing toothed belt pulley
  231
• 3.4 Measuring axial play of camshaft
  236
• 3.5 Removing and installing camshaft oil seal
  237
• 3.6 Removing and installing camshaft control valve 1 N205
  243
• 3.7 Removing and installing valve stem seals
  244
• 4 Inlet and exhaust valves
  254
• 4.1 Checking valve guides
  254
• 4.2 Checking valves
  255
• 4.3 Valve dimensions
  255
• Lubrication
  256
• 1 Sump, oil pump
  256
• 1.1 Assembly overview - sump/oil pump
  256
• 1.2 Removing and installing lower part of sump
  259
• 1.3 Removing and installing oil pump
  265
• 1.4 Removing and installing upper part of sump
  267
• 1.5 Engine oil:
  272
• 2 Engine oil cooler
  273
• 2.1 Assembly overview - engine oil cooler
  273
• 2.2 Removing and installing engine oil cooler
  273
• 3 Crankcase ventilation
  275
• 3.1 Assembly overview - crankcase breather system
  275
• 3.2 Removing and installing oil separator
  276
• 4 Oil filter, oil pressure switch
  279
• 4.1 Assembly overview - oil filter/oil pressure switch
  279
• 4.2 Removing and installing oil pressure switch F1
  279
• 4.3 Checking oil pressure
  281
• 4.4 Removing and installing oil filter housing
  282
• Cooling
  284
• 1 Cooling system/coolant
  284
• 1.1 Connection diagram - coolant hoses
  284
• 1.2 Draining and adding coolant
  287
• 1.3 Checking cooling system for leaks
  296
• 2 Coolant pump, regulation of cooling system
  300
• 2.1 Assembly overview - coolant pump, thermostat
  300
• 2.2 Assembly overview - coolant temperature sender
  303
• 2.3 Removing and installing coolant pump
  304
• 2.4 Removing and installing toothed belt pulley for coolant pump
  308
• 2.5 Removing and installing thermostat
  309
• 2.6 Removing and installing coolant temperature sender G62
  313
• 2.7 Removing and installing radiator outlet coolant temperature sender G83
  315
• 3 Coolant pipes
  317
• 3.1 Assembly overview - coolant pipes
  317
• 3.2 Removing and installing coolant pipes
  317
• 4 Radiator, radiator fan
  320
• 4.1 Assembly overview – radiator/radiator fan
  320
• 4.2 Assembly overview – radiator cowl and radiator fan
  324
• 4.3 Removing and installing radiator
  326
• 4.4 Removing and installing radiator cowl
  339
• 4.5 Removing and installing radiator fan V7
  342
• Mixture preparation - injection
  345
• 1 Injection system
  345
• 1.1 Overview of fitting locations - injection system
  345
• 1.2 Assembly overview - fuel system
  351
• 2 Injectors
  354
• 2.1 Assembly overview - fuel rail with injectors
  354
• 2.2 Removing and installing fuel rail
  354
• 2.3 Removing and installing injectors
  357
• 2.4 Checking injectors
  358
• 2.5 Cleaning injectors
  362
• 3 Air filter
  364
• 3.1 Assembly overview - air filter housing
  364
• 3.2 Removing and installing air filter housing
  366
• 4 Intake manifold
  369
• 4.1 Assembly overview – intake manifold
  369
• 4.2 Removing and installing intake manifold
  373
• 4.3 Removing and installing throttle valve module GX3
  376
• 4.4 Cleaning throttle valve module GX3
  376
• 5 Senders and sensors
  378
• 5.1 Removing and installing intake manifold sender GX9
  378
• 6 Engine control unit
  379
• 6.1 Removing and installing engine control unit J623
  379
• 7 Lambda probe
  391
• 7.1 Assembly overview - Lambda probe
  391
• 7.2 Removing and installing Lambda probe
  392
• Exhaust system
  395
• 1 Exhaust pipes and silencers
  395
• 1.1 Assembly overview – silencers
  395
• 1.2 Separating exhaust pipes from silencers
  405
• 1.3 Removing and installing silencer
  407
• 1.4 Aligning exhaust system free of stress
  414
• 1.5 Checking exhaust system for leaks
  415
• 2 Emission control
  416
• 2.1 Assembly overview – emission control
  416
• 2.2 Removing and installing catalytic converter
  420
• Ignition system
  424
• 1 Ignition system
  424
• 1.1 Assembly overview - ignition system
  424
• 1.2 Removing and installing ignition coils with output stage
  426
• 1.3 Removing and installing knock sensor 1 G61
  428
• 1.4 Removing and installing Hall sender
  430
• 1.5 Removing and installing engine speed sender G28
  430