2-cylinder common rail engine (0.8 l, 4V, turbocharger)

Chapter overview

• Technical data
  1
• 1 Safety instructions
  1
• 1.1 Safety precautions when working on vehicles with high-voltage system
  1
• 1.2 Safety precautions when working on fuel supply 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
  5
• 3.1 Rules for cleanliness
  5
• 3.2 Foreign objects in engine
  5
• 3.3 Contact corrosion
  5
• 3.4 Routing and securing lines
  5
• 3.5 Installing coolers, condensers and radiators
  6
• Removing and installing engine
  7
• 1 Removing and installing engine
  7
• 1.1 Removing engine
  7
• 1.2 Securing engine to workshop hoist
  20
• 1.3 Installing engine
  21
• 1.4 Separating engine and gearbox
  22
• 2 Assembly mountings
  32
• 2.1 Assembly overview - assembly mountings
  32
• 2.2 Removing and installing console for engine mounting
  33
• 2.3 Removing and installing engine mountings
  34
• 2.4 Removing and installing console for gearbox mounting
  36
• 2.5 Removing and installing gearbox mounting
  37
• Crankshaft group
  40
• 1 Cylinder block (pulley end)
  40
• 1.1 Assembly overview - cylinder block, pulley end
  40
• 1.2 Removing and installing vibration damper
  40
• 1.3 Renewing crankshaft oil seal - belt pulley end
  42
• 1.4 Removing and installing engine support
  43
• 2 Cylinder block, gearbox end
  45
• 2.1 Assembly overview - cylinder block, gearbox end
  45
• 2.2 Removing and installing sealing flange on gearbox side
  45
• 3 Crankshaft
  53
• 3.1 Assembly overview - crankshaft
  53
• 3.2 Crankshaft dimensions
  54
• 3.3 Measuring axial clearance of crankshaft
  54
• 4 Pistons and conrods
  56
• 4.1 Assembly overview - pistons and conrods
  56
• 4.2 Removing and installing pistons
  57
• 4.3 Separating new conrod
  58
• 4.4 Measuring piston projection at TDC
  58
• Cylinder head, valve gear
  61
• 1 Cylinder head
  61
• 1.1 Assembly overview - cylinder head
  61
• 1.2 Removing and installing cylinder head
  62
• 2 Toothed belt drive
  66
• 2.1 Assembly overview - toothed belt
  66
• 2.2 Removing and installing toothed belt guard
  66
• 2.3 Removing and installing toothed belt
  70
• 2.4 Adjusting valve timing
  73
• 3 Valve gear
  76
• 3.1 Assembly overview - valve gear
  76
• 3.2 Removing and installing camshaft module
  77
• 3.3 Removing and installing camshaft adjuster
  79
• Lubrication
  84
• 1 Sump, oil pump
  84
• 1.1 Assembly overview - sump and oil pump
  84
• 1.2 Removing and installing oil level and oil temperature sender G266
  86
• 1.3 Removing and installing lower part of sump
  86
• 1.4 Removing and installing upper part of sump
  89
• 1.5 Removing and installing oil pump
  91
• 1.6 Engine oil
  91
• 1.7 Clearing oil warning display
  92
• 2 Oil filter, oil pressure switch
  94
• 2.1 Assembly overview - oil filter housing, oil pressure switch
  94
• 2.2 Assembly overview - oil filter
  95
• 2.3 Removing and installing oil filter housing
  95
• 2.4 Removing and installing oil pressure switch F1
  96
• 2.5 Removing and installing oil pressure regulating valve N428
  96
• 3 Oil circuit
  98
• 3.1 Removing and installing oil supply line/oil return line
  98
• Cooling
  100
• 1 Cooling system, coolant
  100
• 1.1 Coolant hose schematic diagram
  100
• 1.2 Overview of fitting locations - coolant hoses
  103
• 1.3 Draining and filling coolant
  105
• 1.4 Checking cooling system for leaks
  112
• 2 Coolant pump, regulation of cooling system
  115
• 2.1 Assembly overview - coolant pump, thermostat
  115
• 2.2 Assembly overview - coolant temperature sender
  116
• 2.3 Assembly overview - electric coolant pump
  116
• 2.4 Removing and installing coolant pump
  118
• 2.5 Removing and installing thermostat
  120
• 2.6 Removing and installing switch valve for mechanical coolant pump N649 for cylinder head
  120
• 2.7 Removing and installing coolant temperature sender G62
  120
• 2.8 Removing and installing engine temperature sender G407
  121
• 3 Coolant pipes
  122
• 3.1 Assembly overview - coolant pipes
  122
• 3.2 Removing and installing coolant pipes
  122
• 4 Radiator and radiator fan
  129
• 4.1 Assembly overview - radiator
  129
• 4.2 Assembly overview - radiator cowl and radiator fan
  130
• 4.3 Assembly overview - air duct
  131
• 4.4 Removing and installing radiator
  131
• 4.5 Removing and installing radiator cover
  134
• 4.6 Removing and installing regulating valve for cooling air flaps N648
  138
• 5 Adapter cable for coolant shortage indicator
  142
• 5.1 Installing adapter cable for coolant shortage indicator
  142
• Fuel supply system
  148
• 1 Fuel cooler
  148
• 1.1 Assembly overview - fuel cooler
  148
• 2 Fuel tank
  149
• 2.1 Assembly overview - fuel tank
  149
• 2.2 Removing and installing fuel tank
  149
• 3 Fuel delivery unit and fuel gauge sender
  151
• 3.1 Assembly overview - fuel delivery unit and fuel gauge sender
  151
• 4 Fuel filter
  152
• 4.1 Removing and installing fuel filter
  152
• 5 Accelerator mechanism
  153
• 5.1 Assembly overview - accelerator module
  153
• 6 Fuel pump
  155
• 6.1 Removing and installing fuel pump control unit J538
  155
• Turbocharging/supercharging
  157
• 1 Turbocharger
  157
• 1.1 Assembly overview - turbocharger
  157
• 1.2 Removing and installing turbocharger
  158
• 2 Charge air system
  161
• 2.1 Assembly overview - charge air system
  161
• 2.2 Removing and installing charge air cooler
  162
• 2.3 Removing and installing charge pressure sender G31
  165
• 2.4 Removing and installing charge air temperature sender ahead of charge air cooler G810
  165
• 2.6 Removing and installing charge air pipe
  166
• Mixture preparation - injection
  168
• 1 Injection system
  168
• 1.1 Overview of fitting locations - injection system
  168
• 1.2 Checking fuel system for leaks
  169
• 1.3 Filling and bleeding fuel system
  169
• 2 Vacuum system
  171
• 2.1 Schematic diagram - vacuum system
  171
• 2.2 Testing vacuum system
  171
• 3 Injectors and fuel rail
  173
• 3.1 Assembly overview - injectors
  173
• 3.2 Assembly overview - fuel rail
  174
• 3.3 Removing and installing injectors
  175
• 3.4 Removing and installing high-pressure lines
  177
• 3.5 Removing and installing fuel rail
  178
• 3.6 Adapting correction values for injectors
  179
• 4 Air filter
  181
• 4.1 Assembly overview - air filter housing
  181
• 4.2 Removing and installing air filter housing
  181
• 5 Intake manifold
  184
• 5.1 Assembly overview - intake manifold
  184
• 5.2 Removing and installing intake manifold
  184
• 5.3 Removing and installing throttle valve module J338
  184
• 6 Senders and sensors
  187
• 6.1 Removing and installing fuel pressure regulating valve N276
  187
• 6.2 Removing and installing fuel pressure sender G247
  188
• 6.3 Removing and installing pressure differential sender G505
  188
• 6.4 Pressure differential sender 2 G524
  190
• 6.5 Removing and installing air mass meter G70
  192
• 7 Engine control unit
  194
• 7.1 Removing and installing engine control unit J623
  194
• 8 High-pressure pump
  197
• 8.1 Assembly overview - high-pressure pump
  197
• 8.2 Removing and installing high-pressure pump
  198
• 9 Lambda probe
  200
• 9.1 Assembly overview - Lambda probe
  200
• Exhaust system
  202
• 1 Exhaust pipes, silencers
  202
• 1.1 Assembly overview - silencers
  202
• 1.2 Removing and installing rear silencer
  203
• 2 Emission control
  208
• 2.1 Assembly overview - emission control
  208
• 2.2 Removing and installing particulate filter
  209
• 3 Exhaust gas temperature regulation
  213
• 3.1 Assembly overview - exhaust gas temperature regulation
  213
• 4 Exhaust gas recirculation
  215
• 4.1 Assembly overview - exhaust gas recirculation
  215
• 4.2 Removing and installing exhaust gas recirculation cooler
  216
• 4.3 Removing and installing exhaust gas recirculation pipe
  218
• 4.4 Removing and installing exhaust gas recirculation valve
  219
• 5 Exhaust manifold
  220
• 5.1 Assembly overview - exhaust manifold
  220
• 5.2 Removing and installing exhaust manifold
  220
• Glow plug system
  223
• 1 Glow plug system
  223
• 1.1 Assembly overview - glow plug system
  223
• 1.2 Removing and installing glow plugs Q35 / Q36
  224
• 1.3 Removing and installing automatic glow period control unit J179
  225
• 1.4 Removing and installing Hall sender G40
  226
• 1.5 Removing and installing engine speed sender G28
  227