3-Cyl. injection engine (1.0l, 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 cooling system
  4
• 2.4 Safety measures when working on the ignition system
  5
• 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
  8
• 4.4 Foreign bodies on the engine
  9
• 4.5 Contact corrosion
  9
• 4.6 Connection installation and fastening
  9
• 4.7 Radiator and capacitor installation
  9
• Removing and installing engine
  10
• 1 Engine - remove and install
  10
• 1.1 Engine - removal
  10
• 1.2 Engine - separate gearbox
  24
• 1.3 Engine in the gearbox and engine support - secure
  26
• 1.4 Engine - installation
  28
• 2 Power-drive unit supports
  31
• 2.1 Power unit brackets - assembly overview
  31
• 2.2 Power unit bracket (engine) - remove and install
  33
• 2.3 Power unit bracket (gearbox) - remove and install
  34
• 2.4 Pendulum support (torque limiter) - remove and install
  35
• 2.5 Support the engine in assembly position
  36
• 2.6 Support for power-unit - adjust
  44
• 2.7 Additional notes and installation works in vehicles with air conditioning
  44
• Crankshaft group
  46
• 1 Cylinder block (pulley side)
  46
• 1.1 Poly-V belt mechanism - assembly overview
  46
• 1.2 Poly-V belt - remove and install
  48
• 1.3 Poly-V belt tensioner - remove and install
  50
• 1.4 Crankshaft pulley (vibration damper) - remove and install
  50
• 1.5 Engine console - remove and install
  55
• 1.6 Crankshaft seal (pulley side) - replace
  57
• 2 Cylinder block (gearbox side)
  61
• 2.1 Cylinder block (gearbox side) - assembly overview
  61
• 2.2 Flywheel - remove and install
  63
• 2.3 Crankshaft flange (flywheel side) - replace
  65
• 3 Crankshaft
  78
• 3.1 Crankshaft dimensions
  78
• 3.2 Crankshaft axial clearance - check
  78
• 4 Pistons and conrods
  80
• 4.1 Pistons and conrods - assembly overview
  80
• 4.2 Pistons - remove and install
  83
• 4.3 Pistons, rings, and cylinders - check
  84
• 4.4 Conrod and cap (new part) - separate
  87
• 4.5 Conrod radial clearance - check
  87
• 4.6 Oil spray jet and valve - remove and install
  88
• Cylinder head, valve gear
  90
• 1 Engine cylinder head
  90
• 1.1 Engine cylinder head - assembly overview
  90
• 1.2 Cylinder head cover with exhaust and inlet camshafts - assembly overview
  92
• 1.3 Cylinder head - remove and install
  94
• 1.4 Cylinder head cover with exhaust and inlet camshafts - remove and install
  100
• 1.5 Cylinder compression - check
  105
• 2 Toothed belt drive
  108
• 2.1 Console, upper and lower cover of the toothed belt - assembly overview
  108
• 2.2 Toothed belt - assembly overview
  108
• 2.3 Toothed belt - remove and install
  110
• 2.4 Valve timing - check
  114
• 2.5 Camshaft toothed belt - remove
  127
• 3 Camshaft mechanism
  143
• 3.1 Camshaft mechanism - assembly overview
  143
• 3.2 Crankshaft - check axial clearance
  145
• 3.3 Crankshaft seal - replace
  146
• 3.4 Camshaft regulators - remove and install
  153
• 3.6 Valve stem sealant - replace
  155
• 4 Inlet and exhaust valves
  165
• 4.1 Valve guides - check
  165
• 4.2 Valves - check
  166
• 4.3 Valve dimensions
  166
• Lubrication
  167
• 1 Crankcase/oil pump
  167
• 1.1 Crankcase/oil pump - assembly overview
  167
• 1.2 Lower sump - remove and install
  170
• 1.3 Upper crankcase - remove and install
  172
• 1.4 Oil pump - remove and install
  176
• 1.5 Engine oil
  178
• 2 Engine oil cooler
  180
• 2.1 Engine oil cooler - assembly overview
  180
• 2.2 Engine oil cooler - remove and install
  180
• 3 Engine crankcase ventilation
  182
• 3.1 Engine crankcase ventilation - assembly overview
  182
• 3.2 Crankcase ventilation device - remove and install
  183
• 4 Oil filter/Oil pressure switch F1
  187
• 4.1 Oil filter/Oil pressure switch F1 - assembly overview
  187
• 4.2 Oil filter - remove and install
  187
• 4.3 Oil pressure switch 0.3...0.6 bar F1 - remove and install
  188
• 4.4 Oil pressure and Oil pressure switch F1 - check
  190
• Cooling
  193
• 1 Cooling system/coolant
  193
• 1.1 Hose connection diagram for cooling system
  193
• 1.2 Cooling system - check air-tightness
  194
• 1.3 Coolant tank flap - check safety valve
  196
• 1.4 Cooling system - drainage and replenishment
  197
• 2 Water pump/coolant adjustment
  208
• 2.1 Water pump/thermostatic valves - assembly overview
  208
• 2.2 Air intake cooling pump V188 - assembly overview
  211
• 2.3 Coolant temperature sensor - assembly overview
  211
• 2.4 Air intake cooling pump V188 - remove and install
  212
• 2.5 Water pump - remove and install
  214
• 2.6 Thermostat valve - remove and install
  219
• 2.7 Water pump toothed belt - remove and install
  225
• 2.8 Water pump sprocket - remove and install
  228
• 2.9 Coolant temperature sensor G62 - remove and install
  229
• 2.10 Coolant temperature sensor on the radiator outlet G83 - remove and install
  230
• 3 Cooling system pipes
  232
• 3.1 Coolant system line - assembly overview
  232
• 3.2 Cooling system line - remove and install
  232
• 4 Radiator/radiator fan
  235
• 4.1 Radiator/radiator fan - Assembly overview
  235
• 4.2 Fan housing and radiator fan - Assembly overview
  237
• 4.3 Radiator - remove and install
  238
• 4.4 Intake air cooling circuit radiator - remove and install
  243
• 4.5 Fan housing - remove and install
  246
• 4.6 Radiator fan V7 - remove and install
  246
• Fuel supply system
  248
• 1 Fuel tank
  248
• 1.1 Fuel tank - assembly overview
  248
• 1.2 Fuel tank - remove and install
  251
• 1.3 Fuel tank - drain
  256
• 2 Fuel pump (pre-supply pump) G6/Fuel gauge sensor G
  265
• 2.1 Fuel pump (pre-supply pump) G6 and Fuel gauge sensor G - assembly overview
  265
• 2.2 Fuel pump (pre-supply pump) G6/Fuel gauge sensor G - remove and install
  267
• 2.3 Fuel gauge sensor G - remove and install
  271
• 3 Quick-release fastener with button
  274
• 3.1 Quick-release fastener with button - disconnect
  274
• 4 Fuel filter
  280
• 4.1 Fuel filter - remove and install
  280
• 5 Activated charcoal filter system
  282
• 5.1 Activated charcoal filter system - operation
  282
• 5.2 Activated charcoal filter system - assembly overview
  283
• 5.3 Fuel tank ventilation system - check
  284
• 5.4 Activated charcoal filter - remove and install
  292
• 6 Engine power electronic adjustment (electronic accelerator)
  297
• 6.1 Accelerator pedal module (electric throttle) - assembly overview
  297
• 6.2 Accelerator pedal module (electric throttle) - remove and install
  297
• 7 Fuel pump (pre-supply pump) G6
  300
• 7.1 Fuel pump (pre-supply pump) G6 - check
  300
• 7.2 Fuel pump control unit J538 - remove and install
  329
• 8 Transmitters and sensors
  331
• 8.1 Ethanol concentration sensor G708 - remove and install
  331
• Turbocharging/supercharging
  333
• 1 Exhaust gas turbocharger
  333
• 1.1 Exhaust gas turbocharger - Assembly overview
  333
• 1.2 Exhaust gas turbocharger - remove and install
  336
• 1.3 Load pressure control V465 - remove and install
  340
• 1.4 Turbocharger nozzle - remove and install
  342
• 2 Supercharging air system
  345
• 2.1 Supercharging air system - Assembly overview
  345
• 2.2 Air duct - remove and install
  347
• 2.3 Supercharging air intercooler - remove and install
  348
• 2.4 Load pressure sensor GX26 - remove and install
  349
• 2.5 Charge air system - check air-tightness
  350
• Mixture preparation - injection
  353
• 1 Injection system
  353
• 1.1 Injection system - assembly overview
  353
• 1.2 Fuel system - relieve pressure
  357
• 2 Air cleaner
  359
• 2.1 Air filter - assembly overview
  359
• 2.2 Air filter - remove and install
  359
• 3 Intake manifold
  363
• 3.1 Intake manifold - assembly overview
  363
• 3.2 Intake manifold - remove and install
  365
• 3.3 Throttle butterfly valve control unit GX3 - remove and install
  369
• 3.4 Throttle valve control unit GX3 - clean
  370
• 4 Injection valves
  372
• 4.1 Fuel rail with injection valves - assembly overview
  372
• 4.2 Fuel distributor - removal and installation
  374
• 4.3 Injection valves - remove and install
  375
• 4.4 Injection valves - clean
  381
• 5 Transmitters and sensors
  383
• 5.1 Intake manifold sensor GX9 - remove and install
  383
• 5.2 Fuel pressure sensor G247 - remove and install
  384
• 5.3 Fuel pressure sensor G247 - check
  385
• 6 High pressure pump
  388
• 6.1 High pressure pump - assembly overview
  388
• 6.2 High pressure pump - remove and install
  390
• 6.3 High pressure line - remove and install
  392
• 7 Lambda probe
  395
• 7.1 Lambda probe - assembly overview
  395
• 8 Engine control unit J623
  399
• 8.1 Engine control unit J623 - assembly overview
  399
• 8.2 Engine control unit J623 - remove and install
  399
• 8.3 Engine control unit J623 support - remove and install
  401
• Exhaust system
  403
• 1 Silencer/exhaust pipes
  403
• 1.1 Rear muffler with supports - assembly overview
  403
• 1.2 Silencer/exhaust pipes - detach
  404
• 1.3 Silencer - remove and install
  406
• 1.4 Exhaust system - tension free alignment
  408
• 1.5 Exhaust system - check air-tightness
  408
• 1.6 Double clamp - installation position
  409
• 2 Exhaust system
  411
• 2.1 Front exhaust pipe with catalytic converter - assembly overview
  411
• 2.2 Front exhaust pipe with catalytic converter - remove and install
  414
• Ignition system
  418
• 1 Ignition system
  418
• 1.1 Ignition system - assembly overview
  418
• 1.2 Spark plugs Q - technical data
  420
• 1.3 Ignition coil with final power stage - remove and install
  420
• 1.4 Knock sensor 1 G61 - remove and install
  423
• 1.5 Hall Sensor G40 - remove and install
  424
• 1.6 Engine speed sensor G28 - remove and install
  425