3-cylinder direct-injection engine (1.0 l engine, 4V, EA 211)

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
• 1.6 Safety precautions when working on exhaust system
  3
• 2 Identification
  4
• 2.1 Engine number/engine data
  4
• 3 Repair instructions
  6
• 3.1 Rules for cleanliness
  6
• 3.2 General information
  7
• 3.3 Foreign objects in engine
  7
• 3.4 Contact corrosion
  8
• 3.5 Routing and attachment of lines
  8
• 3.6 Fitting radiator and condensers
  8
• 3.7 Checking vacuum system
  8
• Removing and installing engine
  10
• 1 Removing and installing engine
  10
• 1.1 Removing engine
  10
• 1.2 Separating engine and gearbox
  18
• 1.3 Securing engine on engine and gearbox support
  20
• 1.4 Installing engine
  21
• 2 Assembly mountings
  26
• 2.1 Assembly overview - assembly mountings
  26
• 2.2 Removing and installing engine mounting
  28
• 2.3 Removing and installing gearbox mounting
  30
• 2.4 Removing and installing pendulum support
  32
• 2.5 Supporting engine in installation position
  33
• 2.6 Adjusting assembly mountings
  35
• 2.7 Checking adjustment of assembly mountings
  38
• Crankshaft group
  40
• 1 Cylinder block (pulley end)
  40
• 1.1 Assembly overview - poly V-belt drive
  40
• 1.2 Removing and installing poly-V belt
  44
• 1.3 Removing and installing tensioner for poly V-belt
  48
• 1.4 Removing and installing vibration damper
  49
• 1.5 Removing and installing engine support
  53
• 1.6 Renewing crankshaft oil seal - belt pulley end
  57
• 2 Cylinder block, gearbox end
  61
• 2.1 Assembly overview - cylinder block, gearbox end
  61
• 2.2 Removing and installing flywheel
  62
• 2.3 Removing and installing sealing flange on gearbox side
  63
• 3 Crankshaft
  74
• 3.1 Crankshaft dimensions
  74
• 3.2 Renewing needle bearing in crankshaft
  74
• 3.3 Measuring axial clearance of crankshaft
  77
• 4 Pistons and conrods
  79
• 4.1 Assembly overview - pistons and conrods
  79
• 4.2 Removing and installing pistons
  82
• 4.3 Checking pistons and cylinder bores
  83
• 4.4 Separating new conrod
  85
• 4.5 Checking radial clearance of conrods
  86
• 4.6 Removing and installing oil spray jets
  86
• Cylinder head, valve gear
  88
• 1 Cylinder head
  88
• 1.1 Assembly overview - cylinder head
  88
• 1.2 Assembly overview - camshaft housing
  90
• 1.3 Removing and installing cylinder head
  92
• 1.4 Removing and installing camshaft housing
  96
• 1.5 Checking compression
  100
• 2 Toothed belt drive
  103
• 2.1 Assembly overview - toothed belt cover
  103
• 2.2 Assembly overview - toothed belt
  103
• 2.3 Removing and installing toothed belt
  105
• 2.4 Checking valve timing
  111
• 2.5 Adjusting valve timing
  116
• 2.6 Removing toothed belt from camshaft
  119
• 3 Valve gear
  124
• 3.1 Assembly overview - valve gear
  124
• 3.2 Measuring axial play of camshaft
  126
• 3.3 Removing and installing camshaft oil seal
  127
• 3.4 Removing and installing camshaft adjuster
  134
• 3.5 Removing and installing camshaft control valve 1 N205
  135
• 3.6 Removing and installing exhaust camshaft control valve 1 N318
  136
• 3.7 Removing and installing valve stem seals
  137
• 4 Inlet and exhaust valves
  147
• 4.1 Reworking valve seats
  147
• 4.2 Checking valve guides
  149
• 4.3 Checking valves
  150
• 4.4 Valve dimensions
  150
• Lubrication
  151
• 1 Sump, oil pump
  151
• 1.1 Assembly overview - sump/oil pump
  151
• 1.2 Engine oil:
  155
• 1.3 Removing and installing sump
  156
• 1.4 Removing and installing oil pump
  162
• 1.5 Removing and installing oil level and oil temperature sender G266
  164
• 2 Engine oil cooler
  165
• 2.1 Assembly overview - engine oil cooler
  165
• 2.2 Removing and installing engine oil cooler
  165
• 3 Crankcase ventilation
  167
• 3.1 Assembly overview - crankcase breather system
  167
• 3.2 Removing and installing oil separator
  168
• 4 Oil filter, oil pressure switch
  172
• 4.1 Assembly overview - oil filter/oil pressure switch
  172
• 4.2 Removing and installing oil pressure sender G10
  174
• 4.3 Checking oil pressure
  175
• 4.4 Removing and installing oil pressure regulating valve N428
  176
• Cooling
  178
• 1 Cooling system/coolant
  178
• 1.1 Connection diagram - coolant hoses
  178
• 1.2 Checking cooling system for leaks
  180
• 1.3 Draining and adding coolant
  182
• 2 Coolant pump, regulation of cooling system
  190
• 2.1 Assembly overview - coolant pump, thermostat
  190
• 2.2 Assembly overview - electric coolant pump
  193
• 2.3 Assembly overview - coolant temperature sender
  194
• 2.4 Removing and installing electric coolant pump
  195
• 2.5 Removing and installing coolant pump
  197
• 2.6 Removing and installing thermostat
  203
• 2.7 Removing and installing toothed belt pulley for coolant pump
  207
• 2.8 Removing and installing coolant temperature sender G62
  209
• 2.9 Removing and installing radiator outlet coolant temperature sender G83
  211
• 3 Coolant pipes
  213
• 3.1 Assembly overview - coolant pipes
  213
• 3.2 Removing and installing coolant pipes
  213
• 4 Radiator, radiator fan
  216
• 4.1 Assembly overview - radiator/radiator fan
  216
• 4.2 Assembly overview – radiator cowl and radiator fan
  218
• 4.3 Removing and installing radiator
  219
• 4.4 Removing and installing radiator cowl with radiator fan
  223
• 4.5 Removing and installing radiator fan V7
  225
• Turbocharging/supercharging
  227
• 1 Turbocharger
  227
• 1.1 Assembly overview - turbocharger
  227
• 1.2 Removing and installing turbocharger
  229
• 1.3 Removing and installing charge pressure positioner V465
  235
• 2 Charge air system
  238
• 2.1 Assembly overview - charge air system
  238
• 2.2 Removing and installing charge air cooler
  241
• 2.4 Checking charge air system for leaks
  244
• 2.5 Removing and installing air pipe
  246
• Mixture preparation - injection
  248
• 1 Injection system
  248
• 1.1 Overview of fitting locations - injection system
  248
• 2 Injectors
  252
• 2.1 Assembly overview - fuel rail with injectors
  252
• 2.2 Removing and installing fuel rail
  254
• 2.3 Removing and installing injectors
  254
• 2.4 Renewing seals on injectors
  259
• 2.5 Cleaning injectors
  264
• 3 Air filter
  266
• 3.1 Assembly overview - air filter housing
  266
• 3.2 Removing and installing air filter housing
  267
• 4 Intake manifold
  270
• 4.1 Assembly overview – intake manifold
  270
• 4.2 Removing and installing intake manifold
  272
• 4.3 Removing and installing throttle valve module GX3
  275
• 4.4 Cleaning throttle valve module
  276
• 5 Senders and sensors
  278
• 5.1 Removing and installing fuel pressure sender G247
  278
• 5.2 Checking fuel pressure sender G247
  279
• 5.3 Removing and installing exhaust gas pressure sensor 1 G450
  282
• 5.4 Removing and installing intake manifold sender GX9
  283
• 6 Engine control unit
  284
• 6.1 Removing and installing engine (motor) control unit J623 with protective housing
  284
• 7 High-pressure pump
  287
• 7.1 Assembly overview - high-pressure pump
  287
• 7.2 Removing and installing high-pressure pump
  288
• 7.3 Removing and installing high-pressure pipe
  289
• 8 Lambda probe
  291
• 8.1 Assembly overview - Lambda probe
  291
• 8.2 Removing and installing Lambda probe
  292
• Exhaust system
  294
• 1 Exhaust pipes and silencers
  294
• 1.1 Assembly overview – silencers
  294
• 1.2 Separating exhaust pipes from silencers
  295
• 1.3 Aligning exhaust system free of stress
  297
• 1.4 Checking exhaust system for leaks
  298
• 1.5 Installation position of clamp
  298
• 2 Emission control
  301
• 2.1 Assembly overview – emission control
  301
• 2.2 Removing and installing catalytic converter
  304
• Ignition system
  307
• 1 Ignition system
  307
• 1.1 Assembly overview - ignition system
  307
• 1.2 Removing and installing ignition coils with output stage
  309
• 1.3 Removing and installing knock sensor 1 G61
  311
• 1.4 Removing and installing Hall sender
  312
• 1.5 Removing and installing engine speed sender G28
  313