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

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 notes
  7
• 3.1 Rules for cleanliness
  7
• 3.2 General information
  7
• 3.3 General repair instructions
  8
• 3.4 Foreign objects in engine
  8
• 3.5 Contact corrosion
  8
• 3.6 Pipe/wire routing and attachment
  9
• 3.7 Installing radiators and condensers
  9
• 3.8 Checking vacuum system
  9
• Removing and installing engine
  10
• 1 Removing and installing motor
  10
• 1.1 Removing motor
  10
• 1.2 Separating engine and gearbox
  23
• 1.3 Securing engine on engine and gearbox support
  27
• 1.4 Installing engine
  30
• 2 Assembly mountings
  34
• 2.1 Assembly overview – assembly mountings
  34
• 2.2 Removing and installing engine mounting
  40
• 2.3 Removing and installing gearbox mounting
  43
• 2.4 Removing and installing pendulum support
  47
• 2.5 Supporting engine in installation position
  48
• 2.6 Adjusting assembly mountings
  58
• 2.7 Checking adjustment of assembly mountings (engine and gearbox mountings)
  61
• Crankshaft group
  62
• 1 Cylinder block (pulley end)
  62
• 1.1 Assembly overview - poly V-belt drive
  62
• 1.2 Removing and installing poly-V belt
  66
• 1.3 Removing and installing tensioner for poly V-belt
  69
• 1.4 Removing and installing vibration damper
  70
• 1.5 Removing and installing engine support
  73
• 1.6 Renewing crankshaft oil seal - belt pulley end
  76
• 1.7 Removing and installing sealing flange on pulley end
  79
• 2 Cylinder block, gearbox end
  83
• 2.1 Assembly overview - cylinder block, gearbox end
  83
• 2.2 Removing and installing flywheel
  85
• 2.3 Removing and installing sealing flange on gearbox side
  87
• 3 Crankshaft
  98
• 3.1 Crankshaft dimensions
  98
• 3.2 Renewing needle bearing in crankshaft
  98
• 3.3 Measuring axial clearance of crankshaft
  101
• 4 Pistons and conrods
  103
• 4.1 Assembly overview - pistons and conrods
  103
• 4.2 Removing and installing pistons
  106
• 4.3 Checking pistons and cylinder bores
  107
• 4.4 Separating new conrod
  109
• 4.5 Checking radial clearance of conrods
  110
• 4.6 Removing and installing oil spray jets
  110
• 4.7 Setting piston to TDC position
  111
• Cylinder head, valve gear
  115
• 1 Cylinder head
  115
• 1.1 Assembly overview - cylinder head
  115
• 1.2 Assembly overview - camshaft housing
  117
• 1.3 Removing and installing cylinder head
  120
• 1.4 Removing and installing camshaft housing
  124
• 1.5 Checking compression
  128
• 2 Toothed belt drive
  131
• 2.1 Assembly overview - toothed belt cover
  131
• 2.2 Assembly overview - toothed belt
  131
• 2.3 Removing and installing toothed belt guard
  134
• 2.4 Removing and installing toothed belt
  135
• 2.5 Preassembling and installing test tool VAS 611 007
  138
• 2.6 Checking valve timing
  146
• 2.7 Adjusting valve timing
  148
• 2.8 Removing toothed belt from camshaft
  159
• 3 Valve gear
  166
• 3.1 Assembly overview - valve gear
  166
• 3.2 Removing and installing camshaft oil seal
  169
• 3.3 Removing and installing camshaft adjuster
  181
• 3.4 Removing and installing inlet camshaft control valve 1 N727
  191
• 3.5 Removing and installing exhaust camshaft control valve 1 N318
  192
• 3.6 Removing and installing valve stem seals
  193
• 3.7 Removing and installing holder for oil seal
  207
• 4 Inlet and exhaust valves
  210
• 4.1 Checking valve guides
  210
• 4.2 Checking valves
  211
• 4.3 Valve dimensions
  211
• Lubrication
  212
• 1 Sump, oil pump
  212
• 1.1 Assembly overview - sump/oil pump
  212
• 1.2 Engine oil:
  216
• 1.3 Removing and installing sump
  216
• 1.4 Removing and installing oil pump
  221
• 1.5 Removing and installing oil level and oil temperature sender G266
  222
• 2 Engine oil cooler
  224
• 2.1 Assembly overview - engine oil cooler
  224
• 2.2 Removing and installing engine oil cooler
  225
• 3 Crankcase ventilation
  226
• 3.1 Assembly overview - crankcase breather system
  226
• 3.2 Removing and installing oil separator
  227
• 4 Oil filter, oil pressure switch
  230
• 4.1 Assembly overview - oil filter/oil pressure switch
  230
• 4.2 Removing and installing oil pressure sender G10
  231
• 4.3 Checking oil pressure and oil pressure switch
  232
• 4.4 Removing and installing oil filter housing
  232
• 4.5 Removing and installing oil pressure regulating valve N428
  233
• 4.6 Removing and installing piston cooling jet control valve N522
  234
• Cooling
  236
• 1 Cooling system/coolant
  236
• 1.1 Connection diagram - coolant hoses
  236
• 1.2 Checking cooling system for leaks
  237
• 1.3 Draining and adding coolant
  240
• 2 Coolant pump, regulation of cooling system
  250
• 2.1 Assembly overview - coolant pump, thermostat
  250
• 2.2 Assembly overview - electric coolant pump
  252
• 2.3 Assembly overview - coolant temperature sender
  252
• 2.4 Removing and installing electric coolant pump
  253
• 2.5 Removing and installing coolant pump
  255
• 2.6 Removing and installing toothed belt pulley for coolant pump
  261
• 2.7 Removing and installing coolant temperature sender G62
  263
• 2.8 Removing and installing radiator outlet coolant temperature sender G83
  265
• 2.9 Removing and installing engine outlet coolant temperature sender G82
  266
• 2.10 Removing and installing engine temperature regulation module GX33
  269
• 2.11 Checking coolant pump
  271
• 3 Coolant pipes
  277
• 3.1 Assembly overview - coolant pipes
  277
• 3.2 Removing and installing coolant pipes
  278
• 4 Radiator, radiator fan
  281
• 4.1 Assembly overview – radiator
  281
• 4.2 Assembly overview - radiator cowl and radiator fan
  286
• 4.3 Assembly overview - radiator blind
  286
• 4.4 Removing and installing radiator
  289
• 4.5 Removing and installing radiator cowl
  306
• 4.6 Removing and installing radiator fan V7
  307
• 4.7 Removing and installing radiator blind
  308
• 4.8 Removing and installing radiator blind control motor V544
  310
• Turbocharging/supercharging
  316
• 1 Turbocharger
  316
• 1.1 Assembly overview - turbocharger
  316
• 1.2 Removing and installing turbocharger
  319
• 1.3 Removing and installing charge pressure control module GX34
  325
• 1.4 Removing and installing connection for turbocharger
  326
• 2 Charge air system
  328
• 2.1 Assembly overview - charge air system
  328
• 2.2 Removing and installing charge air cooler
  330
• 2.3 Removing and installing charge pressure sender GX26
  331
• 2.4 Checking charge air system for leaks
  332
• 2.5 Removing and installing air pipe
  336
• Mixture preparation - injection
  339
• 1 Injection system
  339
• 1.1 Overview of fitting locations - injection system
  339
• 2 Injectors
  346
• 2.1 Assembly overview - fuel rail with injectors
  346
• 2.2 Removing and installing fuel rail
  348
• 2.3 Removing and installing injectors
  349
• 3 Air filter
  357
• 3.1 Assembly overview - air filter housing
  357
• 3.2 Removing and installing air filter housing
  359
• 3.3 Removing air duct on lock carrier
  362
• 4 Intake manifold
  365
• 4.1 Assembly overview - intake manifold
  365
• 4.2 Removing and installing intake manifold
  367
• 4.3 Removing and installing throttle valve module GX3
  369
• 4.4 Cleaning throttle valve module GX3
  370
• 5 Senders and sensors
  372
• 5.1 Removing and installing fuel pressure sender G247
  372
• 5.2 Checking fuel pressure sender G247
  373
• 5.3 Removing and installing intake manifold sender GX9
  375
• 5.4 Removing and installing exhaust gas pressure sensor 1 G450
  375
• 6 Engine control unit
  377
• 6.1 Assembly overview - engine control unit
  377
• 6.2 Removing and installing engine control unit J623
  377
• 7 High-pressure pump
  383
• 7.1 Assembly overview - high-pressure pump
  383
• 7.2 Removing and installing high-pressure pump
  384
• 7.3 Removing and installing high-pressure pipe
  386
• 8 Lambda probe
  388
• 8.1 Assembly overview - Lambda probe
  388
• 8.2 Removing and installing Lambda probe
  389
• Exhaust system
  391
• 1 Exhaust pipes and silencers
  391
• 1.1 Assembly overview – silencers
  391
• 1.2 Separating exhaust pipes from silencers
  395
• 1.3 Removing and installing silencer
  396
• 1.4 Aligning exhaust system free of stress
  401
• 1.5 Checking exhaust system for leaks
  401
• 1.6 Installation position of clamp
  402
• 2 Emission control
  404
• 2.1 Assembly overview - emission control
  404
• 2.2 Removing and installing catalytic converter
  407
• 2.3 Removing and installing particulate filter
  410
• Ignition system
  411
• 1 Ignition system
  411
• 1.1 Assembly overview - ignition system
  411
• 1.2 Removing and installing ignition coils with output stage
  413
• 1.3 Removing and installing knock sensor 1 G61
  416
• 1.4 Removing and installing engine speed sender G28
  417
• 1.5 Removing and installing inlet camshaft position sender G1002
  419
• 1.6 Removing and installing exhaust camshaft position sender G1003
  420