3-Cyl. injection engine (1.0 l)

Chapter overview

• 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 cooling system
  4
• 2.4 Safety measures when working on the ignition system
  4
• 3 Identification
  6
• 3.1 Engine number/engine characteristics
  6
• 4 Repair instructions
  8
• 4.1 Cleanliness rules
  8
• 4.2 General instructions
  8
• 4.3 General repair instructions
  9
• 4.4 Foreign bodies on the engine
  9
• 4.5 Contact corrosion
  9
• 4.6 Connection installation and fastening
  10
• 4.7 Radiator and capacitor installation
  10
• 4.8 Check the vacuum system
  10
• Removing and installing engine
  11
• 1 Engine - remove and install
  11
• 1.1 Engine - removal
  11
• 1.2 Engine - separate gearbox
  22
• 1.3 Engine - secure to engine and gearbox support
  24
• 1.4 Engine - installation
  26
• 1.5 Engine - remove and install, summarized instructions
  29
• 2 Power-drive unit supports
  32
• 2.1 Power unit brackets - assembly overview
  32
• 2.2 Power unit bracket (engine side) - remove and install
  35
• 2.3 Drive-train mounting (gearbox side) - remove and install
  36
• 2.4 Pendulum support (torque limiter) - remove and install
  39
• 2.5 Support the engine in assembly position
  40
• 2.6 Drive train mountings - adjust
  42
• 2.7 Drive train mounting adjustment - check
  44
• Crankshaft group
  45
• 1 Cylinder block (pulley side)
  45
• 1.1 Poly-V belt mechanism - assembly overview
  45
• 1.2 Cylinder block (pulley side) - assembly overview
  47
• 1.3 Poly-V belt - remove and install
  50
• 1.4 Poly-V belt tensioner - remove and install
  52
• 1.5 Engine console - remove and install
  53
• 1.6 Crankshaft pulley (vibration damper) - remove and install
  57
• 1.7 Crankshaft seal (pulley side) - replace
  60
• 2 Cylinder block (gearbox side)
  63
• 2.1 Cylinder block (gearbox side) - assembly overview
  63
• 2.2 Flywheel - remove and install
  64
• 2.3 Crankshaft flange (flywheel side) - replace
  66
• 3 Crankshaft
  78
• 3.1 Crankshaft - dimensions
  78
• 4 Pistons and conrods - remove and install
  79
• 4.1 Pistons and conrods - assembly overview
  79
• 4.2 Pistons - remove and install
  82
• 4.3 Pistons, rings, and cylinders - check
  83
• 4.4 Conrod and cap (new part) - separate
  86
• 4.5 Conrod radial clearance - check
  86
• 4.6 Oil spray jet and valve - remove and install
  87
• Cylinder head, valve gear
  89
• 1 Engine cylinder head
  89
• 1.1 Engine cylinder head - assembly overview
  89
• 1.2 Cylinder head - remove and install
  92
• 1.3 Cylinder head - remove and install, summarized instructions
  99
• 1.4 Cylinder head cover with exhaust and inlet camshafts - remove and install
  101
• 1.5 Cylinder compression - check
  104
• 2 Toothed belt drive
  107
• 2.1 Toothed belt - remove and install
  107
• 2.2 Valve timing - check
  111
• 2.3 Remove the camshaft toothed belt
  115
• 3 Camshaft mechanism
  128
• 3.1 Camshaft mechanism - assembly overview
  128
• 3.2 Crankshaft - check axial clearance
  130
• 3.3 Camshaft gasket (pulley side) - replace
  131
• 3.4 Inlet camshaft regulator - remove and install
  138
• 3.5 Exhaust camshaft sprocket - remove and install
  143
• 3.6 Camshaft adjustment valve 1 N205 - remove and install
  147
• 3.7 Valve stem sealant - replace
  148
• 4 Inlet and exhaust valves
  159
• 4.1 Valve guides - check
  159
• 4.2 Valves - check
  160
• 4.3 Valve dimensions
  160
• Lubrication
  161
• 1 Crankcase/oil pump
  161
• 1.1 Crankcase/oil pump - assembly overview
  161
• 1.2 Engine oil
  166
• 1.3 Lower sump - remove and install
  167
• 1.4 Upper crankcase - remove and install
  169
• 1.5 Oil pump - remove and install
  173
• 2 Engine crankcase ventilation
  176
• 2.1 Engine crankcase ventilation - assembly overview
  176
• 2.2 Crankcase ventilation device - remove and install
  177
• 3 Oil filter/Oil pressure switch F1
  180
• 3.1 Oil pressure switch 0.3...0.6 bar F1 - remove and install
  180
• 3.2 Oil pressure and Oil pressure switch F1 - check
  181
• 3.3 Oil filter - remove and install
  184
• Cooling
  186
• 1 Cooling system/coolant
  186
• 1.1 Hose connection diagram for cooling system
  186
• 1.2 Cooling system - check air-tightness
  186
• 1.3 Coolant tank flap - check safety valve
  189
• 1.4 Cooling system - drainage and replenishment
  191
• 2 Water pump/coolant adjustment
  198
• 2.1 Water pump/thermostatic valves - assembly overview
  198
• 2.2 Thermostat valve - assembly overview
  201
• 2.3 Water pump - remove and install
  204
• 2.4 Thermostats - remove and install
  209
• 2.5 Water pump toothed belt - remove and install
  215
• 2.6 Water pump sprocket - remove and install
  216
• 2.7 Coolant temperature sensor G62 - remove and install
  218
• 3 Cooling system pipes
  221
• 3.1 Coolant system line - assembly overview
  221
• 3.2 Cooling system line - remove and install
  221
• 4 Radiator/Radiator fan
  223
• 4.1 Radiator/Radiator fan - assembly overview
  223
• 4.2 Fan cowl and radiator fan - assembly overview
  224
• 4.3 Radiator - remove and install
  225
• 4.4 Fan housing - remove and install
  231
• 4.5 Radiator fan V7 - remove and install
  233
• Fuel supply system
  234
• 1 Fuel tank
  234
• 1.1 Fuel tank - assembly overview
  234
• 1.2 Fuel tank - remove and install
  236
• 1.3 Fuel tank - drain
  243
• 2 Fuel supply unit/Fuel level sensor
  254
• 2.1 Fuel pump (pre-supply pump) G6/Fuel gauge sensor G - assembly overview
  254
• 2.2 Fuel pump (pre-supply pump) G6/Fuel gauge sensor G - remove and install
  256
• 2.3 Fuel gauge sensor G - remove and install
  261
• 2.4 Installation opening cover - remove and install
  262
• 3 Plug-in connectors
  264
• 3.1 Plug-in connectors - disconnect
  264
• 4 Fuel filter
  270
• 4.1 Fuel filter - remove and install
  270
• 5 Activated charcoal system
  272
• 5.1 Activated charcoal filter system - assembly overview
  272
• 5.2 Activated charcoal filter - remove and install
  274
• 5.3 Fuel tank ventilation - check
  275
• 6 Accelerator activation
  282
• 6.1 Accelerator pedal module - assembly overview
  282
• 6.2 Accelerator pedal module GX2 - remove and install
  282
• 7 Fuel system pressurisation pump G6
  284
• 7.1 Fuel system pressurisation pump G6 - check
  284
• 8 Fuel lines
  303
• 8.1 Fuel lines - remove and install
  303
• Mixture preparation - injection
  308
• 1 Injection system
  308
• 1.1 Injection system - assembly overview
  308
• 1.2 Combustion system - assembly overview
  311
• 2 Injection valves
  314
• 2.1 Fuel rail with injection valves - assembly overview
  314
• 2.2 Injection valves - remove and install
  316
• 2.3 Injection valves - check
  318
• 3 Air cleaner
  325
• 3.1 Air filter - assembly overview
  325
• 3.2 Air filter - remove and install
  326
• 4 Intake manifold
  328
• 4.1 Intake manifold - assembly overview
  328
• 4.2 Intake manifold - remove and install
  330
• 4.3 Throttle butterfly valve control unit J338 - remove and install
  333
• 4.4 Throttle valve control unit J338 - clean
  335
• 5 Transmitters and sensors
  337
• 6 Engine control unit J623
  339
• 6.1 Engine control unit J623 - remove and install
  339
• 7 Lambda probe
  341
• 7.1 Lambda probe - assembly overview
  341
• 7.2 Lambda Probe G39 - remove and install
  342
• 7.3 Lambda Probe after the catalytic converter G130 - remove and install
  343
• Exhaust system
  346
• 1 Silencer/exhaust pipes
  346
• 1.1 Silencer - assembly overview
  346
• 1.2 Silencer/exhaust pipes - detach
  347
• 1.3 Centre silencer with rear silencer - remove and install
  349
• 1.4 Centre silencer - remove and install
  353
• 1.5 Rear silencer - remove and install
  355
• 1.6 Exhaust system - tension free alignment
  356
• 1.7 Exhaust system - check tightness
  357
• 1.8 Pipe clamp installation position
  357
• 2 Exhaust system
  359
• 2.1 Emission control - assembly overview
  359
• 2.2 Catalytic converter - remove and install
  362
• Ignition system
  365
• 1 Ignition system
  365
• 1.1 Ignition system - assembly overview
  365
• 1.2 Ignition coils with final power stage - assembly overview
  367
• 1.3 Spark plugs Q - technical data
  368
• 1.4 Ignition coil with final power stage - remove and install
  368
• 1.5 Knock sensor 1 G61 - remove and install
  372
• 1.6 Hall Sensor G40 - remove and install
  373
• 1.7 Engine speed sensor G28 - remove and install
  374
• 1.8 Heater control unit J65 - remove and install
  376