1.6 l engine, 4V, EA 211

Chapter overview

• Technical data
  1
• 1 Identification
  1
• 1.1 Engine number/engine data
  1
• 2 Safety information
  2
• 2.1 Safety regulations for working on fuel supply
  2
• 2.2 Safety measures when working on vehicles with a start/stop system
  2
• 2.4 Safety precautions when working on the cooling system
  3
• 2.5 Safety precautions when working on ignition system
  3
• 2.6 Safety precautions when working on exhaust system
  4
• 3 Repair instructions
  5
• 3.1 Rules for cleanliness
  5
• 3.2 General information
  5
• 3.3 Foreign objects in engine
  5
• 3.4 Contact corrosion
  6
• 3.5 Routing and attachment of lines
  6
• 3.6 Checking vacuum system
  6
• Removing and installing engine
  8
• 1 Removing and installing engine
  8
• 1.1 Removing engine
  8
• 1.2 Separating engine and gearbox
  13
• 1.3 Securing engine on engine and gearbox support
  15
• 1.4 Installing engine
  17
• 2 Assembly mountings
  19
• 2.1 Assembly overview - assembly mountings
  19
• 2.2 Removing and installing engine mounting
  21
• 2.3 Removing and installing gearbox mounting
  22
• 2.4 Removing and installing pendulum support
  23
• 2.5 Supporting engine in installation position
  24
• 2.6 Adjusting assembly mountings
  28
• 2.7 Checking adjustment of assembly mountings
  30
• Crankshaft group
  31
• 1 Cylinder block (pulley end)
  31
• 1.1 Assembly overview - cylinder block (pulley end)
  31
• 1.2 Assembly overview - sealing flange, belt pulley end
  33
• 1.3 Removing and installing poly-V belt
  33
• 1.4 Removing and installing tensioner for poly V-belt
  34
• 1.5 Removing and installing vibration damper
  35
• 1.6 Removing and installing engine support
  36
• 1.7 Renewing crankshaft oil seal - belt pulley end
  38
• 1.8 Removing and installing sealing flange on pulley end
  40
• 2 Cylinder block, gearbox end
  41
• 2.1 Assembly overview - cylinder block, gearbox end
  41
• 2.2 Removing and installing flywheel
  43
• 2.3 Removing and installing sealing flange on gearbox side
  44
• 2.4 Removing and installing intermediate plate
  54
• 3 Crankshaft
  56
• 3.1 Crankshaft dimensions
  56
• 3.2 Measuring axial clearance of crankshaft
  56
• 4 Pistons and conrods
  58
• 4.1 Assembly overview - pistons and conrods
  58
• 4.2 Removing and installing pistons
  61
• 4.3 Checking pistons and cylinder bores
  63
• 4.4 Separating new conrod
  65
• 4.5 Checking radial clearance of conrods
  66
• 4.6 Removing and installing oil spray jets
  66
• 4.7 Setting piston to TDC position
  67
• Cylinder head, valve gear
  70
• 1 Cylinder head
  70
• 1.1 Assembly overview - cylinder head
  70
• 1.2 Assembly overview - camshaft housing
  72
• 1.3 Removing and installing cylinder head
  74
• 1.4 Removing and installing camshaft housing
  78
• 1.5 Checking compression
  80
• 2 Toothed belt drive
  82
• 2.1 Assembly overview - toothed belt cover
  82
• 2.2 Assembly overview - toothed belt
  82
• 2.3 Removing and installing toothed belt guard
  84
• 2.4 Removing and installing toothed belt
  85
• 2.5 Checking valve timing
  89
• 2.6 Preassembling and installing valve timing tool
  91
• 2.7 Adjusting valve timing
  99
• 2.8 Removing toothed belt from camshaft
  109
• 3 Valve gear
  111
• 3.1 Assembly overview - valve gear
  111
• 3.2 Measuring axial play of camshaft
  113
• 3.3 Removing and installing camshaft oil seal
  114
• 3.4 Removing and installing camshaft adjuster
  121
• 3.5 Removing and installing camshaft control valve 1 N205
  124
• 3.6 Removing and installing valve stem seals
  124
• 3.7 Removing and installing toothed belt pulley
  131
• 4 Inlet and exhaust valves
  134
• 4.1 Checking valve guides
  134
• 4.2 Checking valves
  135
• 4.3 Valve dimensions
  135
• Lubrication
  136
• 1 Sump, oil pump
  136
• 1.1 Assembly overview - sump/oil pump
  136
• 1.2 Engine oil:
  139
• 1.3 Removing and installing lower part of sump
  139
• 1.4 Removing and installing upper part of sump
  143
• 1.5 Removing and installing oil pump
  145
• 2 Engine oil cooler
  147
• 2.1 Assembly overview - engine oil cooler
  147
• 2.2 Removing and installing engine oil cooler
  147
• 3 Crankcase ventilation
  149
• 3.1 Assembly overview - crankcase breather system
  149
• 3.2 Removing and installing oil separator
  150
• 4 Oil filter, oil pressure switch
  153
• 4.1 Assembly overview - oil filter/oil pressure switch
  153
• 4.2 Removing and installing oil pressure switch F1
  153
• 4.3 Checking oil pressure
  154
• Cooling
  157
• 1 Cooling system/coolant
  157
• 1.1 Connection diagram - coolant hoses
  157
• 1.2 Checking cooling system for leaks
  158
• 1.3 Draining and adding coolant
  160
• 2 Coolant pump, regulation of cooling system
  167
• 2.1 Assembly overview - coolant pump, thermostat
  167
• 2.2 Assembly overview - coolant temperature sender
  170
• 2.3 Removing and installing coolant pump
  171
• 2.4 Removing and installing thermostat
  174
• 2.5 Removing and installing toothed belt for coolant pump
  176
• 2.6 Removing and installing toothed belt pulley for coolant pump
  177
• 2.7 Removing and installing coolant temperature sender G62
  178
• 2.8 Removing and installing radiator outlet coolant temperature sender G83
  179
• 3 Coolant pipes
  181
• 3.1 Assembly overview - coolant pipes
  181
• 3.2 Removing and installing coolant pipes
  181
• 4 Radiator, radiator fan
  186
• 4.1 Assembly overview - radiator, radiator fan
  186
• 4.2 Assembly overview – radiator cowl and radiator fan
  187
• 4.3 Removing and installing radiator
  188
• 4.4 Removing and installing radiator cowl
  191
• 4.5 Removing and installing radiator fan VX57
  192
• 4.6 Removing and installing radiator fan 2 V177
  193
• Mixture preparation - injection
  195
• 1 Injectors
  195
• 1.1 Assembly overview - fuel rail with injectors
  195
• 1.2 Removing and installing fuel rail
  195
• 1.3 Removing and installing injectors
  197
• 1.4 Cleaning injectors
  198
• 2 Air filter
  200
• 2.1 Assembly overview - air filter housing
  200
• 2.2 Removing and installing air filter housing
  202
• 2.3 Removing and installing air guide on lock carrier
  202
• 3 Intake manifold
  204
• 3.1 Assembly overview – intake manifold
  204
• 3.2 Removing and installing intake manifold
  205
• 3.3 Removing and installing throttle valve module GX3
  207
• 3.4 Cleaning throttle valve module GX3
  208
• 4 Senders and sensors
  209
• 4.1 Removing and installing intake manifold sender GX9
  209
• 5 Engine control unit
  210
• 5.1 Removing and installing engine control unit J623
  210
• 6 Lambda probe
  212
• 6.1 Assembly overview - Lambda probe
  212
• 6.2 Removing and installing Lambda probe 1 before catalytic converter GX10
  212
• 6.3 Removing and installing Lambda probe 1 after catalytic converter GX7
  214
• Exhaust system
  217
• 1 Exhaust pipes and silencers
  217
• 1.1 Assembly overview – silencers
  217
• 1.2 Separating exhaust pipes from silencers
  219
• 1.3 Removing and installing front silencer
  220
• 1.4 Removing and installing centre silencer
  221
• 1.5 Removing and installing rear silencer
  222
• 1.6 Aligning exhaust system free of stress
  223
• 1.7 Checking exhaust system for leaks
  224
• 1.8 Installation position of clamp
  225
• 2 Emission control
  226
• 2.1 Assembly overview – emission control
  226
• 2.2 Removing and installing catalytic converter
  227
• Ignition system
  230
• 1 Ignition system
  230
• 1.1 Assembly overview - ignition system
  230
• 1.2 Removing and installing ignition coils
  232
• 1.3 Removing and installing knock sensor 1 G61
  233
• 1.4 Removing and installing Hall sender G40
  234
• 1.5 Removing and installing engine speed sender G28
  235