3-cyl. injection engine (1.0 l engine, 4V, EA 211 EVO)

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety regulations for working on fuel supply
  1
• 1.2 Safety measures when working on vehicles with a start/stop system
  1
• 1.4 Safety precautions when working on the cooling system
  2
• 1.5 Safety precautions when working on ignition system
  2
• 2 Identification
  3
• 2.1 Engine number/engine data
  3
• 3 Repair instructions
  5
• 3.1 Rules for cleanliness
  5
• 3.2 General information
  5
• 3.3 General repair instructions
  5
• 3.4 Foreign objects in engine
  6
• 3.5 Contact corrosion
  6
• 3.6 Routing and attachment of lines
  6
• 3.7 Fitting radiator and condensers
  6
• 3.8 Checking vacuum system
  7
• Removing and installing engine
  8
• 1 Removing and installing engine
  8
• 1.1 Removing motor
  8
• 1.2 Separating engine and gearbox
  30
• 1.3 Securing engine on engine and gearbox support
  31
• 1.4 Installing engine
  34
• 2 Assembly mountings
  38
• 2.1 Assembly overview - assembly mountings
  38
• 2.2 Removing and installing engine mounting
  44
• 2.3 Removing and installing gearbox mountings
  46
• 2.4 Removing and installing pendulum support
  50
• 2.5 Supporting engine in installation position
  51
• 2.6 Adjusting assembly mountings
  60
• 2.7 Checking adjustment of assembly mountings (engine and gearbox mountings)
  62
• Crankshaft group
  64
• 1 Cylinder block (pulley end)
  64
• 1.1 Assembly overview - poly V-belt drive
  64
• 1.2 Removing and installing poly-V belt
  68
• 1.3 Removing and installing tensioner for poly V-belt
  72
• 1.4 Removing and installing vibration damper
  73
• 1.5 Removing and installing engine support
  77
• 1.6 Renewing crankshaft oil seal - belt pulley end
  79
• 1.7 Removing and installing sealing flange on pulley end
  82
• 2 Cylinder block, gearbox end
  86
• 2.1 Assembly overview - cylinder block, gearbox end
  86
• 2.2 Removing and installing flywheel
  87
• 2.3 Removing and installing sealing flange on gearbox side
  89
• 3 Crankshaft
  100
• 3.1 Crankshaft dimensions
  100
• 4 Pistons and conrods
  101
• 4.1 Assembly overview - pistons and conrods
  101
• 4.2 Checking pistons and cylinder bores
  103
• 4.3 Separating new conrod
  106
• 4.4 Removing and installing oil spray jets
  106
• 4.5 Setting piston to TDC position
  108
• Cylinder head, valve gear
  111
• 1 Cylinder head
  111
• 1.1 Assembly overview - cylinder head
  111
• 1.2 Removing and installing cylinder head
  114
• 1.3 Removing and installing camshaft housing
  120
• 1.4 Checking compression
  125
• 2 Toothed belt drive
  128
• 2.1 Assembly overview - toothed belt cover
  128
• 2.2 Assembly overview - toothed belt
  129
• 2.3 Removing and installing toothed belt guard
  132
• 2.4 Removing and installing toothed belt
  133
• 2.5 Preassembling and installing valve timing tool
  143
• 2.6 Checking valve timing
  151
• 2.7 Adjusting valve timing
  154
• 2.8 Removing toothed belt from camshaft
  165
• 3 Valve gear
  173
• 3.1 Assembly overview - valve gear
  173
• 3.2 Removing and installing camshaft oil seal
  176
• 3.3 Removing and installing camshaft adjuster
  187
• 3.4 Removing and installing camshaft control valve 1 N727
  197
• 3.5 Removing and installing exhaust camshaft control valve 1 N318
  198
• 3.6 Removing and installing valve stem seals
  198
• 3.7 Removing and installing holder for oil seal
  208
• 4 Inlet and exhaust valves
  212
• 4.1 Checking valve guides
  212
• Lubrication
  214
• 1 Sump, oil pump
  214
• 1.1 Assembly overview - sump/oil pump
  214
• 1.2 Engine oil:
  220
• 1.3 Removing and installing oil sump
  221
• 1.4 Removing and installing oil pump
  225
• 1.5 Removing and installing oil level and oil temperature sender G266
  229
• 2 Crankcase ventilation
  230
• 2.1 Assembly overview - crankcase breather system
  230
• 2.2 Removing and installing oil separator
  231
• 3 Oil filter, oil pressure switch
  232
• 3.1 Assembly overview - oil pressure switches/oil pressure control
  232
• 3.2 Removing and installing oil pressure sender G10
  233
• 3.3 Checking oil pressure and oil pressure switch
  234
• 3.4 Removing and installing oil filter housing
  234
• 3.5 Removing and installing oil pressure regulating valve N428
  235
• Cooling
  237
• 1 Cooling system/coolant
  237
• 1.1 Connection diagram - coolant hoses
  237
• 1.2 Checking cooling system for leaks
  237
• 1.3 Draining and adding coolant
  241
• 2 Coolant pump, regulation of cooling system
  259
• 2.1 Assembly overview - coolant pump, thermostat
  259
• 2.2 Assembly overview - coolant temperature sender
  261
• 2.3 Removing and installing coolant pump
  261
• 2.4 Removing and installing toothed belt pulley for coolant pump
  266
• 2.5 Removing and installing coolant temperature sender G62
  268
• 2.6 Removing and installing engine outlet coolant temperature sender G82
  271
• 2.7 Removing and installing engine temperature regulation module GX33
  273
• 2.8 Checking coolant pump
  276
• 3 Coolant pipes
  282
• 3.1 Assembly overview - coolant pipes
  282
• 3.2 Removing and installing coolant pipes
  283
• 4 Radiator, radiator fan
  284
• 4.1 Assembly overview - radiator/radiator fan
  284
• 4.2 Assembly overview - radiator cowl and radiator fan
  287
• 4.3 Removing and installing radiator
  288
• 4.4 Removing and installing radiator cowl with radiator fan
  299
• 4.5 Removing and installing radiator fan VX57
  303
• Mixture preparation - injection
  304
• 1 Injection system
  304
• 1.1 Overview of fitting locations - injection system
  304
• 2 Injectors
  308
• 2.1 Assembly overview - fuel rail with injectors
  308
• 2.2 Removing and installing injectors
  309
• 2.3 Checking injectors
  313
• 3 Air filter
  319
• 3.1 Assembly overview - air filter housing
  319
• 3.2 Removing and installing air filter housing
  322
• 3.3 Removing and installing resonator for intake air
  324
• 3.4 Removing air duct on lock carrier
  324
• 4 Intake manifold
  325
• 4.1 Assembly overview - intake manifold
  325
• 4.2 Removing and installing intake manifold
  327
• 4.3 Removing and installing throttle valve module GX3
  330
• 4.4 Cleaning throttle valve module GX3
  332
• 5 Senders and sensors
  334
• 5.1 Removing and installing intake manifold sender GX9
  334
• 5.2 Removing and installing fuel pressure sender for low-pressure G410
  335
• 6 Engine control unit
  336
• 6.1 Assembly overview - engine control unit
  336
• 6.2 Removing and installing engine control unit J623
  337
• 6.3 Removing and installing engine (motor) control unit J623 with protective housing
  339
• 7 Lambda probe
  344
• 7.1 Assembly overview - Lambda probe
  344
• 7.2 Removing and installing Lambda probe
  345
• Exhaust system
  350
• 1 Exhaust pipes and silencers
  350
• 1.1 Assembly overview - silencers
  350
• 1.2 Separating exhaust pipes from silencers
  352
• 1.3 Removing and installing silencer
  354
• 1.4 Aligning exhaust system free of stress
  359
• 1.5 Checking exhaust system for leaks
  359
• 1.6 Installation position of clamp
  360
• 2 Emission control
  364
• 2.1 Assembly overview - emission control
  364
• 2.2 Removing and installing catalytic converter
  367
• Ignition system
  371
• 1 Ignition system
  371
• 1.1 Assembly overview - ignition system
  371
• 1.2 Removing and installing ignition coils with output stage
  373
• 1.3 Removing and installing knock sensor 1 G61
  376
• 1.4 Removing and installing engine speed sender G28
  376
• 1.5 Removing and installing inlet camshaft position sender G1002
  381
• 1.6 Removing and installing exhaust camshaft position sender G1003
  382