3-Cyl. injection engine (1.0 l, turbocharger)

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 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 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
  24
• 1.3 Engine - secure to engine and gearbox support
  29
• 1.4 Engine - installation
  31
• 1.5 Engine - remove and install, summarized instructions
  35
• 2 Power-drive unit supports
  38
• 2.1 Power unit brackets - assembly overview
  38
• 2.2 Power unit bracket (engine side) - remove and install
  41
• 2.3 Drive-train mounting (gearbox side) - remove and install
  42
• 2.4 Pendulum support (torque limiter) - remove and install
  44
• 2.5 Support the engine in assembly position
  46
• 2.6 Drive train mountings - adjust
  55
• 2.7 Drive train mounting adjustment - check
  57
• Crankshaft group
  59
• 1 Cylinder block (pulley side)
  59
• 1.1 Poly-V belt mechanism - assembly overview
  59
• 1.2 Poly-V belt - remove and install
  61
• 1.3 Poly-V belt tensioner - remove and install
  63
• 1.4 Crankshaft pulley (vibration damper) - remove and install
  63
• 1.5 Engine console - remove and install
  67
• 1.6 Crankshaft seal (pulley side) - replace
  72
• 2 Cylinder block (gearbox side)
  75
• 2.1 Cylinder block (gearbox side) - assembly overview
  75
• 2.2 Flywheel - remove and install
  79
• 2.3 Clutch Disk - removal and installation
  81
• 2.4 Crankshaft flange (flywheel side) - replace
  83
• 3 Crankshaft
  96
• 3.1 Crankshaft - dimensions
  96
• 4 Pistons and conrods - remove and install
  97
• 4.1 Pistons and conrods - assembly overview
  97
• 4.2 Pistons - remove and install
  100
• 4.3 Pistons, rings, and cylinders - check
  101
• 4.4 Conrod and cap (new part) - separate
  104
• 4.5 Conrod radial clearance - check
  104
• 4.6 Oil spray jet and valve - remove and install
  105
• Cylinder head, valve gear
  107
• 1 Engine cylinder head
  107
• 1.1 Engine cylinder head - assembly overview
  107
• 1.2 Cylinder head cover with exhaust and inlet camshafts - assembly overview
  109
• 1.3 Cylinder head - remove and install
  112
• 1.4 Cylinder head - remove and install, summarized instructions
  116
• 1.5 Cylinder head cover with exhaust and inlet camshafts - remove and install
  118
• 1.6 Cylinder compression - check
  124
• 2 Toothed belt drive
  127
• 2.1 Console, upper and lower cover of the toothed belt - assembly overview
  127
• 2.2 Toothed belt - assembly overview
  127
• 2.3 Toothed belt - remove and install
  129
• 2.4 Valve timing - check
  133
• 2.5 Camshaft toothed belt - remove
  139
• 3 Camshaft mechanism
  155
• 3.1 Camshaft mechanism - assembly overview
  155
• 3.2 Crankshaft - check axial clearance
  157
• 3.3 Camshaft gasket (pulley side) - replace
  158
• 3.4 Inlet and exhaust camshaft regulators - remove and install
  166
• 3.6 Valve stem sealant - replace
  177
• 4 Inlet and exhaust valves
  190
• 4.1 Valve guides - check
  190
• 4.2 Valves - check
  191
• 4.3 Valve dimensions
  191
• Lubrication
  192
• 1 Crankcase/oil pump
  192
• 1.1 Crankcase/oil pump - assembly overview
  192
• 1.2 Lower sump - remove and install
  197
• 1.3 Upper crankcase - remove and install
  199
• 1.4 Oil pump - remove and install
  203
• 1.5 Engine oil
  205
• 2 Engine oil cooler
  207
• 2.1 Engine oil cooler - assembly overview
  207
• 2.2 Engine oil cooler - remove and install
  207
• 3 Engine crankcase ventilation
  209
• 3.1 Engine crankcase ventilation - assembly overview
  209
• 3.2 Crankcase ventilation device - remove and install
  210
• 4 Oil filter/Oil pressure switch F378
  214
• 4.1 Oil filter/Oil pressure switch F378 – assembly overview
  214
• 4.2 Oil filter - remove and install
  214
• 4.3 Oil pressure switch F378 – remove and install
  215
• 4.4 Oil pressure and Oil pressure switch F378 – check
  217
• Cooling
  220
• 1 Cooling system/coolant
  220
• 1.1 Hose connection diagram for cooling system
  220
• 1.2 Cooling system - check air-tightness
  222
• 1.3 Coolant tank flap - check safety valve
  225
• 1.4 Cooling system - drainage and replenishment
  227
• 2 Water pump/coolant adjustment
  236
• 2.1 Water pump/thermostatic valves - assembly overview
  236
• 2.2 Air intake cooling pump V188 - assembly overview
  239
• 2.3 Coolant temperature sensor - assembly overview
  240
• 2.4 Air intake cooling pump V188 - remove and install
  241
• 2.5 Water pump - remove and install
  243
• 2.6 Thermostats - remove and install
  248
• 2.7 Water pump toothed belt - remove and install
  254
• 2.8 Water pump sprocket - remove and install
  257
• 2.9 Coolant temperature sensor G62 - remove and install
  258
• 2.10 Coolant temperature sensor on the radiator outlet G83 - remove and install
  260
• 3 Cooling system pipes
  262
• 3.1 Coolant system line - assembly overview
  262
• 3.2 Cooling system line - remove and install
  262
• 4 Radiator/Radiator fan
  265
• 4.1 Radiator - assembly overview
  265
• 4.2 Fan cowl and radiator fan - assembly overview
  267
• 4.3 Radiator - remove and install
  268
• 4.4 Fan housing - remove and install
  270
• 4.5 Radiator fan V7 - remove and install
  271
• 4.6 Charge air cooling system radiator - remove and install
  272
• Fuel supply system
  276
• 1 Fuel tank
  276
• 1.1 Fuel tank - assembly overview
  276
• 1.2 Fuel tank - remove and install
  278
• 1.3 Fuel tank - drain
  285
• 2 Fuel supply unit/Fuel level sensor
  296
• 2.1 Fuel pump (pre-supply pump) G6/Fuel gauge sensor G - assembly overview
  296
• 2.2 Fuel pump (pre-supply pump) G6/Fuel gauge sensor G - remove and install
  298
• 2.3 Fuel gauge sensor G - remove and install
  303
• 2.4 Installation opening cover - remove and install
  304
• 3 Plug-in connectors
  306
• 3.1 Plug-in connectors - disconnect
  306
• 4 Fuel filter
  312
• 4.1 Fuel filter - remove and install
  312
• 5 Activated charcoal system
  314
• 5.1 Activated charcoal filter system - assembly overview
  314
• 5.2 Activated charcoal filter - remove and install
  316
• 5.3 Fuel tank ventilation - check
  317
• 6 Accelerator activation
  324
• 6.1 Accelerator pedal module - assembly overview
  324
• 6.2 Accelerator pedal module GX2 - remove and install
  324
• 7 Fuel system pressurisation pump G6
  326
• 7.1 Fuel system pressurisation pump G6 - check
  326
• 7.2 Fuel pump control unit J538 - remove and install
  346
• 8 Fuel lines
  348
• 8.1 Fuel lines - remove and install
  348
• Turbocharging/supercharging
  353
• 1 Exhaust gas turbocharger
  353
• 1.1 Exhaust gas turbocharger - Assembly overview
  353
• 1.2 Exhaust gas turbocharger - remove and install
  357
• 1.3 Exhaust gas turbocharger - remove and install, summarized instructions
  362
• 1.4 Load pressure control V465 - remove and install
  363
• 1.5 Turbocharger nozzle - remove and install
  364
• 2 Supercharging air system
  368
• 2.1 Supercharging air system - Assembly overview
  368
• 2.2 Air duct - remove and install
  371
• 2.3 Supercharging air intercooler - remove and install
  372
• 2.4 Load pressure sensor GX26 - remove and install
  373
• 2.5 Charge air system - check air-tightness
  374
• Mixture preparation - injection
  377
• 1 Injection system
  377
• 1.1 Injection system - assembly overview
  377
• 1.2 Fuel system - relieve pressure
  383
• 2 Air filter
  385
• 2.1 Air filter - assembly overview
  385
• 2.2 Air filter - remove and install
  387
• 3 Intake manifold
  390
• 3.1 Intake manifold - assembly overview
  390
• 3.2 Intake manifold - remove and install
  392
• 3.3 Throttle butterfly valve control unit GX3 - remove and install
  396
• 3.4 Throttle valve control unit GX3 - clean
  397
• 4 Injection valves
  399
• 4.1 Fuel rail with injection valves - assembly overview
  399
• 4.2 Fuel distributor - removal and installation
  401
• 4.3 Injection valves - remove and install
  402
• 4.4 Injectors - remove and install, summarized instructions
  409
• 4.5 Injection valves - clean
  411
• 5 Transmitters and sensors
  413
• 5.1 Intake manifold sensor GX9 - remove and install
  413
• 5.2 Fuel pressure sensor G247 - remove and install
  414
• 5.3 Fuel pressure sensor G247 - check
  415
• 5.4 Ethanol concentration sensor G708 - remove and install
  418
• 6 High pressure pump
  420
• 6.1 High pressure pump - assembly overview
  420
• 6.2 High pressure pump - remove and install
  422
• 6.3 High pressure line - remove and install
  424
• 7 Lambda probe
  427
• 7.1 Lambda probe - assembly overview
  427
• 8 Engine control unit J623
  431
• 8.1 Engine control unit J623 - remove and install
  431
• Exhaust system
  433
• 1 Silencer/exhaust pipes
  433
• 1.1 Silencer - assembly overview
  433
• 1.2 Silencer/exhaust pipes - detach
  434
• 1.3 Centre silencer with rear silencer - remove and install
  436
• 1.4 Centre silencer - remove and install
  440
• 1.5 Rear silencer - remove and install
  442
• 1.6 Exhaust system - tension free alignment
  443
• 1.7 Exhaust system - check tightness
  443
• 1.8 Pipe clamp installation position
  444
• 2 Exhaust system
  445
• 2.1 Emission control - assembly overview
  445
• 2.2 Catalytic converter - remove and install
  448
• Ignition system
  452
• 1 Ignition system
  452
• 1.1 Ignition system - assembly overview
  452
• 1.2 Ignition coils with final power stage - assembly overview
  454
• 1.3 Spark plugs Q - technical data
  455
• 1.4 Ignition coil with final power stage - remove and install
  455
• 1.5 Knock sensor 1 G61 - remove and install
  458
• 1.6 Hall Sensor G40 - remove and install
  460
• 1.7 Engine speed sensor G28 - remove and install
  461