4 - Cyl. injection engine (1.6 l) EA211

Kapitelübersicht

• Technical data
  1
• 1 \--- Change history ---
  1
• 2 Safety instructions
  2
• 2.1 Safety measures regarding work on the fuel supply
  2
• 2.2 Safety measures in test drives using testing and measurement devices
  3
• 2.3 Safety measures when working on the ignition system
  4
• 2.4 Safety measures when working on the exhaust system
  4
• 2.5 Safety measures when working on the cooling system
  4
• 3 Identification
  6
• 3.1 Engine number/engine characteristics
  6
• 4 Repair instructions
  8
• 4.1 Cleaning rules
  8
• 4.2 General Notes
  8
• 4.3 General repair instructions
  8
• 4.4 Foreign bodies on the engine
  9
• 4.5 Contact corrosion
  9
• 4.6 Connection installation and fastening
  9
• 4.7 Radiator and capacitor installation
  9
• Removing and installing engine
  10
• 1 Engine - remove and install
  10
• 1.1 Engine - removal
  10
• 1.2 Engine - separate gearbox
  19
• 1.3 Secure the engine to the engine and gearbox swivelling stand
  23
• 1.4 Engine - installation
  25
• 2 Power-drive unit supports
  29
• 2.1 Power unit brackets - assembly overview
  29
• 2.2 Support engine in mounting position
  30
• 2.3 Power-drive unit supports (engine side) - remove and install
  31
• 2.4 Power-drive unit supports (gearbox side) - remove and install
  32
• 2.5 Pendulum support (torque restrictor) - remove and install
  36
• 2.6 Ancillary brackets - check adjustment
  37
• Crankshaft group
  38
• 1 Cylinder block (pulley side)
  38
• 1.1 Poly-V belt - assembly overview
  38
• 1.2 Poly-V belt - remove and install
  39
• 1.3 Poly-V belt tensioner - remove and install
  41
• 1.4 Crankshaft pulley (vibration damper) - remove and install
  41
• 1.5 Engine console - remove and install
  42
• 1.6 Crankshaft seal (pulley side) - replace
  43
• 2 Cylinder block (gearbox side)
  47
• 2.1 Cylinder block (gearbox side) - assembly overview
  47
• 2.2 Flywheel - remove and install
  50
• 2.3 Clutch Disk - removal and installation
  51
• 2.4 Crankshaft flange (flywheel side) - replace
  53
• 3 Crankshaft
  63
• 3.1 Crankshaft dimensions
  63
• 3.2 Crankshaft - check axial clearance
  63
• 4 Pistons and connecting rods
  65
• 4.1 Pistons and conrods - assembly overview
  65
• 4.2 Pistons - remove and install
  68
• 4.3 Pistons, rings, and cylinders - check (conrod with bushing)
  69
• 4.4 Pistons, rings, and cylinders - check (conrod without bushing)
  71
• 4.5 Connecting rod (radial clearance) - check
  73
• 4.6 Oil injectors - remove and install
  73
• Cylinder head, valve gear
  75
• 1 Engine cylinder head
  75
• 1.1 Engine cylinder head - assembly overview
  75
• 1.2 Cylinder head cover with camshafts - assembly overview
  77
• 1.3 Engine cylinder head - remove and install
  78
• 1.4 Cylinder head cover with camshafts - remove and install
  84
• 1.5 Compression - check
  86
• 2 Toothed belt drive
  90
• 2.2 Toothed belt - assembly overview
  91
• 2.3 Mechanical distribution cover - removal and installation
  92
• 2.4 Valve timing - check
  93
• 2.5 Remove the toothed belt from the camshafts
  98
• 2.6 Toothed belt - remove and install
  107
• 3 Camshaft mechanism - repair
  114
• 3.1 Camshaft mechanism - assembly overview
  114
• 3.2 Crankshaft - check axial clearance
  116
• 3.3 Inlet camshaft regulator - remove and install
  117
• 3.4 Exhaust camshaft sprocket - remove and install
  121
• 3.5 Camshaft seal - replace
  125
• 3.6 Camshaft adjustment valve 1 N205 - remove and install
  130
• 3.7 Valve stem sealant - replace
  130
• 4 Inlet and exhaust valves
  140
• 4.1 Valve guides - check
  140
• 4.2 Valves - check
  141
• 4.3 Valves - dimensions
  141
• Lubrication
  142
• 1 Crankcase/oil pump
  142
• 1.1 Crankcase/oil pump - assembly overview
  142
• 1.2 Lower sump - remove and install
  144
• 1.3 Upper crankcase - remove and install
  147
• 1.4 Oil pump - remove and install
  150
• 1.5 Engine oil
  152
• 2 Engine oil cooler
  154
• 2.1 Engine oil cooler - assembly overview
  154
• 2.2 Engine oil cooler - remove and install
  154
• 3 Engine crankcase ventilation
  156
• 3.1 Engine crankcase ventilation - assembly overview
  156
• 3.2 Crankcase ventilation device - remove and install
  157
• 4 Oil filter/ Oil pressure switch F1
  159
• 4.1 Oil filter/ Oil pressure switch F1 - assembly overview
  159
• 4.2 Oil pressure switch 0.3...0.6 bar F1 - remove and install
  159
• 4.3 Oil filter - remove and install
  161
• 4.4 Oil pressure and Oil pressure switch F1 - check
  161
• Cooling
  164
• 1 Cooling system components
  164
• 1.1 Hose connection diagram for cooling system
  164
• 1.2 Cooling system - drainage and replenishment
  166
• 1.3 Cooling system - check air-tightness
  173
• 1.4 Coolant tank flap - check safety valve
  174
• 2 Coolant/cooling system water pump
  176
• 2.1 Water pump - assembly overview
  176
• 2.2 Water pump - remove and install
  178
• 2.3 Water pump sprocket - remove and install
  183
• 2.4 Thermostat valve - removal and installation
  184
• 2.5 Water pump toothed belt - remove and install
  192
• 2.6 Coolant temperature sensor G62 - remove and install
  194
• 3 Radiator
  197
• 3.1 Radiator/ Radiator fan V7 - assembly overview
  197
• 3.2 Radiator - remove and install
  199
• 3.3 Cowling with Radiator fan V7 - remove and install
  201
• 3.4 Radiator fan V7 - remove and install
  202
• Fuel supply system
  203
• 1 Fuel supply system components
  203
• 1.1 Fuel tank - assembly overview
  203
• 1.2 Fuel reservoir - remove and install
  205
• 1.3 Fuel tank - drain
  208
• 1.4 Cold start system components - remove and install
  215
• 1.5 Fuel shutoff in case of crash
  216
• 2 Fuel supply unit/ Fuel level sensor G
  217
• 2.1 Fuel pump (pre-supply pump) G6 - remove and install
  217
• 2.2 Fuel gauge sensor G - remove and install
  219
• 3 Quick-release fastener with button
  221
• 3.1 Quick-release fastener with button - disconnect
  221
• 4 Fuel filter
  225
• 4.1 Fuel filter - remove and install
  225
• 5 Activated charcoal filter system
  226
• 5.1 Operation
  226
• 5.2 Activated charcoal filter system components - repair
  226
• 5.3 Fuel tank ventilation - check
  227
• 6 Engine power electronic adjustment (electronic accelerator)
  229
• 6.2 Electronic accelerator system operation
  229
• 7 Fuel pump (pre-supply pump) G6
  231
• 7.1 Fuel pump (pre-supply pump) G6 - check
  231
• Mixture preparation - injection
  243
• 1 Injection system
  243
• 1.1 Sensors, switches (intake side) - assembly overview
  243
• 1.2 Sensor, ignition coils and lambda probe (exhaust side) - assembly overview
  244
• 1.3 Injection system - assembly overview
  244
• 2 Injection valves
  248
• 2.1 Fuel rail with injection valves - assembly overview
  248
• 2.2 Injection valves - remove and install
  251
• 2.3 Injection valves - check
  255
• 2.4 Injection valves - clean
  258
• 3 Air cleaner
  260
• 3.1 Air filter - assembly overview
  260
• 3.2 Air filter - remove and install
  261
• 4 Intake manifold
  262
• 4.1 Intake manifold - assembly overview
  262
• 4.2 Intake manifold - remove and install
  263
• 4.3 Throttle butterfly valve control unit J338 - remove and install
  265
• 4.4 Throttle valve control unit J338 - clean
  266
• 4.5 Supply system pressure, fuel pressure gauge and residual pressure - check
  267
• 5 READINESS code
  274
• 5.1 Function
  274
• 5.2 Creating and Interpreting the READINESS code
  274
• 6 Transmitters and sensors
  275
• 7 Engine control unit J623
  277
• 7.1 Engine control unit J623 - remove and install
  277
• 8 Lambda probe
  281
• 8.1 Lambda probe - assembly overview
  281
• 8.2 Lambda probe - remove and install
  282
• Exhaust system
  285
• 1 Exhaust pipes/silencers
  285
• 1.1 Exhaust pipes/silencers - exploded view
  285
• 1.2 Separate exhaust pipes/silencers
  286
• 1.3 Silencers - remove and install
  286
• 1.4 Exhaust system - free of stress alignment
  287
• 1.5 Exhaust system - check air-tightness
  287
• 1.6 Pipe clamp installation position
  288
• 2 Exhaust gas purging
  289
• 2.1 Front exhaust pipe with catalytic converters - assembly overview
  289
• 2.2 Front exhaust pipe with catalytic converters - remove and install
  290
• Ignition system
  293
• 1 Ignition system
  293
• 1.1 Ignition system - assembly overview
  293
• 1.2 Ignition coils with final power stage - assembly overview
  295
• 1.3 Test data, spark plugs
  295
• 1.4 Ignition coil with final power stage - remove and install
  296
• 1.5 Knock sensor 1 G61 - remove and install
  299
• 1.6 Hall Sensor G40 - remove and install
  299
• 1.7 Engine speed sensor G28 - remove and install
  300