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
  23
• 1.3 Engine - secure to engine and gearbox support
  25
• 1.4 Engine - installation
  28
• 1.5 Engine - remove and install, summarized instructions
  31
• 2 Power-drive unit supports
  34
• 2.1 Power unit brackets - assembly overview
  34
• 2.2 Power unit bracket (engine side) - remove and install
  37
• 2.3 Drive-train mounting (gearbox side) - remove and install
  38
• 2.4 Pendulum support (torque limiter) - remove and install
  40
• 2.5 Support the engine in assembly position
  42
• 2.6 Drive train mountings - adjust
  47
• 2.7 Drive train mounting adjustment - check
  49
• Crankshaft group
  51
• 1 Cylinder block (pulley side)
  51
• 1.1 Poly-V belt mechanism - assembly overview
  51
• 1.2 Poly-V belt - remove and install
  53
• 1.3 Poly-V belt tensioner - remove and install
  55
• 1.4 Crankshaft pulley (vibration damper) - remove and install
  55
• 1.5 Engine console - remove and install
  59
• 1.6 Crankshaft seal (pulley side) - replace
  64
• 2 Cylinder block (gearbox side)
  67
• 2.1 Cylinder block (gearbox side) - assembly overview
  67
• 2.2 Flywheel - remove and install
  69
• 2.3 Crankshaft flange (flywheel side) - replace
  71
• 3 Crankshaft
  84
• 3.1 Crankshaft - dimensions
  84
• 4 Pistons and conrods - remove and install
  85
• 4.1 Pistons and conrods - assembly overview
  85
• 4.2 Pistons - remove and install
  88
• 4.3 Pistons, rings, and cylinders - check
  89
• 4.4 Conrod and cap (new part) - separate
  92
• 4.5 Conrod radial clearance - check
  92
• 4.6 Oil spray jet and valve - remove and install
  93
• Cylinder head, valve gear
  95
• 1 Engine cylinder head
  95
• 1.1 Engine cylinder head - assembly overview
  95
• 1.2 Cylinder head cover with exhaust and inlet camshafts - assembly overview
  97
• 1.3 Cylinder head - remove and install
  99
• 1.4 Cylinder head - remove and install, summarized instructions
  105
• 1.5 Cylinder head cover with exhaust and inlet camshafts - remove and install
  107
• 1.6 Cylinder compression - check
  113
• 2 Toothed belt drive
  116
• 2.1 Console, upper and lower cover of the toothed belt - assembly overview
  116
• 2.2 Toothed belt - assembly overview
  116
• 2.3 Toothed belt - remove and install
  118
• 2.4 Valve timing - check
  122
• 2.5 Camshaft toothed belt - remove
  128
• 3 Camshaft mechanism
  143
• 3.1 Camshaft mechanism - assembly overview
  143
• 3.2 Crankshaft - check axial clearance
  145
• 3.3 Camshaft gasket (pulley side) - replace
  146
• 3.4 Intake and exhaust valve camshaft regulator/gear - remove and install
  154
• 3.5 Camshaft adjustment valve 1 N205 - remove and install
  164
• 3.6 Valve stem sealant - replace
  165
• 4 Inlet and exhaust valves
  178
• 4.1 Valve guides - check
  178
• 4.2 Valves - check
  179
• 4.3 Valve dimensions
  179
• Lubrication
  180
• 1 Crankcase/oil pump
  180
• 1.1 Crankcase/oil pump - assembly overview
  180
• 1.2 Lower sump - remove and install
  185
• 1.3 Upper crankcase - remove and install
  187
• 1.4 Oil pump - remove and install
  191
• 1.5 Engine oil
  193
• 2 Engine crankcase ventilation
  195
• 2.1 Engine crankcase ventilation - assembly overview
  195
• 2.2 Crankcase ventilation device - remove and install
  196
• 3 Oil filter/Oil pressure switch F378
  200
• 3.1 Oil filter/Oil pressure switch F378 – assembly overview
  200
• 3.2 Oil filter - remove and install
  200
• 3.3 Oil pressure switch F378 – remove and install
  201
• 3.4 Oil pressure and Oil pressure switch F378 – check
  203
• Cooling
  206
• 1 Cooling system/coolant
  206
• 1.1 Hose connection diagram for cooling system
  206
• 1.2 Cooling system - check air-tightness
  207
• 1.3 Coolant tank flap - check safety valve
  210
• 1.4 Cooling system - drainage and replenishment
  211
• 2 Water pump/coolant adjustment
  220
• 2.1 Water pump/thermostatic valves - assembly overview
  220
• 2.2 Air intake cooling pump V188 - assembly overview
  223
• 2.3 Coolant temperature sensor - assembly overview
  224
• 2.4 Air intake cooling pump V188 - remove and install
  225
• 2.5 Water pump - remove and install
  227
• 2.6 Thermostats - remove and install
  232
• 2.7 Water pump toothed belt - remove and install
  238
• 2.8 Water pump sprocket - remove and install
  241
• 2.9 Coolant temperature sensor G62 - remove and install
  242
• 2.10 Coolant temperature sensor on the radiator outlet G83 - remove and install
  244
• 3 Cooling system pipes
  246
• 3.1 Coolant system line - assembly overview
  246
• 3.2 Cooling system line - remove and install
  246
• 4 Radiator/Radiator fan
  249
• 4.1 Radiator - assembly overview
  249
• 4.2 Fan cowl and radiator fan - assembly overview
  251
• 4.3 Radiator - remove and install
  252
• 4.4 Fan housing - remove and install
  254
• 4.5 Radiator fan V7 - remove and install
  255
• 4.6 Charge air cooling system radiator - remove and install
  256
• Fuel supply system
  260
• 1 Fuel tank
  260
• 1.1 Fuel tank - assembly overview
  260
• 1.2 Fuel tank - remove and install
  262
• 1.3 Fuel tank - drain
  269
• 2 Fuel supply unit/Fuel level sensor
  280
• 2.1 Fuel pump (pre-supply pump) G6/Fuel gauge sensor G - assembly overview
  280
• 2.2 Fuel pump (pre-supply pump) G6/Fuel gauge sensor G - remove and install
  282
• 2.3 Fuel gauge sensor G - remove and install
  287
• 2.4 Installation opening cover - remove and install
  288
• 3 Plug-in connectors
  290
• 3.1 Plug-in connectors - disconnect
  290
• 4 Fuel filter
  296
• 4.1 Fuel filter - remove and install
  296
• 5 Activated charcoal system
  298
• 5.1 Activated charcoal filter system - assembly overview
  298
• 5.2 Activated charcoal filter - remove and install
  300
• 5.3 Fuel tank ventilation - check
  301
• 6 Accelerator activation
  308
• 6.1 Accelerator pedal module - assembly overview
  308
• 6.2 Accelerator pedal module GX2 - remove and install
  308
• 7 Fuel system pressurisation pump G6
  310
• 7.1 Fuel system pressurisation pump G6 - check
  310
• 7.2 Fuel pump control unit J538 - remove and install
  330
• 8 Fuel lines
  332
• 8.1 Fuel lines - remove and install
  332
• Turbocharging/supercharging
  337
• 1 Exhaust gas turbocharger
  337
• 1.1 Exhaust gas turbocharger - Assembly overview
  337
• 1.2 Exhaust gas turbocharger - remove and install
  341
• 1.3 Exhaust gas turbocharger - remove and install, summarized instructions
  346
• 1.4 Load pressure control V465 - remove and install
  347
• 1.5 Turbocharger nozzle - remove and install
  348
• 2 Supercharging air system
  352
• 2.1 Supercharging air system - Assembly overview
  352
• 2.2 Air duct - remove and install
  355
• 2.3 Supercharging air intercooler - remove and install
  356
• 2.4 Load pressure sensor GX26 - remove and install
  357
• 2.5 Charge air system - check air-tightness
  358
• Mixture preparation - injection
  361
• 1 Injection system
  361
• 1.1 Injection system - assembly overview
  361
• 1.2 Fuel system - relieve pressure
  367
• 2 Air cleaner
  369
• 2.1 Air filter - assembly overview
  369
• 2.2 Air filter - remove and install
  371
• 3 Intake manifold
  374
• 3.1 Intake manifold - assembly overview
  374
• 3.2 Intake manifold - remove and install
  376
• 3.3 Throttle butterfly valve control unit GX3 - remove and install
  380
• 3.4 Throttle valve control unit GX3 - clean
  381
• 4 Injection valves
  383
• 4.1 Fuel rail with injection valves - assembly overview
  383
• 4.2 Fuel distributor - removal and installation
  385
• 4.3 Injection valves - remove and install
  386
• 4.4 Injectors - remove and install, summarized instructions
  393
• 4.5 Injection valves - clean
  395
• 5 Transmitters and sensors
  397
• 5.1 Intake manifold sensor GX9 - remove and install
  397
• 5.2 Fuel pressure sensor G247 - remove and install
  398
• 5.3 Fuel pressure sensor G247 - check
  399
• 6 High pressure pump
  403
• 6.1 High pressure pump - assembly overview
  403
• 6.2 High pressure pump - remove and install
  405
• 6.3 High pressure line - remove and install
  407
• 7 Lambda probe
  410
• 7.1 Lambda probe - assembly overview
  410
• 8 Engine control unit J623
  414
• 8.1 Engine control unit J623 - remove and install
  414
• Exhaust system
  416
• 1 Silencer/exhaust pipes
  416
• 1.1 Silencer - assembly overview
  416
• 1.2 Silencer/exhaust pipes - detach
  417
• 1.3 Centre silencer with rear silencer - remove and install
  419
• 1.4 Centre silencer - remove and install
  423
• 1.5 Rear silencer - remove and install
  425
• 1.6 Exhaust system - tension free alignment
  426
• 1.7 Exhaust system - check tightness
  426
• 1.8 Pipe clamp installation position
  427
• 2 Exhaust system
  428
• 2.1 Emission control - assembly overview
  428
• 2.2 Catalytic converter - remove and install
  431
• Ignition system
  435
• 1 Ignition system
  435
• 1.1 Ignition system - assembly overview
  435
• 1.2 Ignition coils with final power stage - assembly overview
  437
• 1.3 Spark plugs Q - technical data
  438
• 1.4 Ignition coil with final power stage - remove and install
  438
• 1.5 Knock sensor 1 G61 - remove and install
  441
• 1.6 Hall Sensor G40 - remove and install
  443
• 1.7 Engine speed sensor G28 - remove and install
  443