3-cylinder direct injection engine (1.0l engine, 4V, EA11, 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
• 2 Identification
  3
• 2.1 Engine number/engine data
  3
• 3 Repair notes
  5
• 3.1 Rules for cleanliness
  5
• 3.2 General information
  5
• 3.3 General repair instructions
  6
• 3.4 Foreign objects in engine
  6
• 3.5 Contact corrosion
  6
• 3.6 Routing and attachment of lines
  7
• 3.7 Fitting radiator and condensers
  7
• 3.8 Checking vacuum system
  7
• Removing and installing engine
  8
• 1 Removing and installing engine
  8
• 1.1 Removing engine
  8
• 1.2 Separating engine and gearbox
  31
• 1.3 Securing engine on engine and gearbox support
  34
• 1.4 Installing engine
  36
• 2 Assembly mountings
  44
• 2.1 Assembly overview - assembly mountings
  44
• 2.2 Removing and installing motor mounting
  49
• 2.3 Removing and installing gearbox mounting
  52
• 2.4 Removing and installing pendulum support
  56
• 2.5 Supporting engine in installation position
  58
• 2.6 Adjusting assembly mountings
  66
• 2.7 Checking adjustment of assembly mountings (engine and gearbox mountings)
  69
• Crankshaft group
  70
• 1 Cylinder block (pulley end)
  70
• 1.1 Assembly overview - poly V-belt drive
  70
• 1.2 Removing and installing poly-V belt
  74
• 1.3 Removing and installing tensioner for poly V-belt
  78
• 1.4 Removing and installing vibration damper
  79
• 1.5 Removing and installing engine support
  82
• 1.6 Renewing crankshaft oil seal - belt pulley end
  86
• 2 Cylinder block, gearbox end
  90
• 2.1 Assembly overview - cylinder block, gearbox end
  90
• 2.2 Removing and installing flywheel
  92
• 2.3 Removing and installing sealing flange on gearbox side
  94
• 3 Crankshaft
  104
• 3.1 Crankshaft dimensions
  104
• 3.2 Renewing needle bearing in crankshaft
  104
• 4 Pistons and conrods
  107
• 4.1 Assembly overview - pistons and conrods
  107
• 4.2 Removing and installing pistons
  110
• 4.3 Checking pistons and cylinder bores
  111
• 4.4 Separating new conrod
  113
• 4.5 Checking radial clearance of conrods
  114
• 4.6 Removing and installing oil spray jets
  114
• 4.7 Setting piston to TDC position
  115
• Cylinder head, valve gear
  119
• 1 Cylinder head
  119
• 1.1 Assembly overview - cylinder head
  119
• 1.2 Assembly overview - camshaft housing
  121
• 1.3 Removing and installing cylinder head
  123
• 1.4 Removing and installing camshaft housing
  127
• 1.5 Checking compression
  131
• 2 Toothed belt drive
  133
• 2.1 Assembly overview - toothed belt cover
  133
• 2.2 Assembly overview - toothed belt
  133
• 2.3 Removing and installing toothed belt
  135
• 2.4 Preassembling and installing test tool VAS 611 007
  141
• 2.5 Checking valve timing
  149
• 2.6 Adjusting valve timing
  152
• 2.7 Removing toothed belt from camshaft
  161
• 3 Valve gear
  169
• 3.1 Assembly overview - valve gear
  169
• 3.2 Measuring axial play of camshaft
  171
• 3.3 Removing and installing camshaft oil seal
  172
• 3.4 Removing and installing camshaft adjuster
  180
• 3.5 Removing and installing camshaft control valve 1 N205
  191
• 3.6 Removing and installing exhaust camshaft control valve 1 N318
  192
• 3.7 Removing and installing valve stem seals
  194
• 4 Inlet and exhaust valves
  205
• 4.1 Checking valve guides
  205
• 4.2 Checking valves
  206
• 4.3 Valve dimensions
  206
• Lubrication
  207
• 1 Sump, oil pump
  207
• 1.1 Assembly overview - sump/oil pump
  207
• 1.2 Engine oil:
  211
• 1.3 Removing and installing sump
  211
• 1.4 Removing and installing oil pump
  217
• 1.5 Removing and installing oil level and oil temperature sender G266
  218
• 2 Engine oil cooler
  220
• 2.1 Assembly overview - engine oil cooler
  220
• 2.2 Removing and installing engine oil cooler
  220
• 3 Crankcase ventilation
  222
• 3.1 Assembly overview - crankcase breather system
  222
• 3.2 Removing and installing oil separator
  223
• 4 Oil filter, oil pressure switch
  227
• 4.1 Assembly overview - oil filter/oil pressure switch
  227
• 4.2 Removing and installing oil pressure sender G10
  228
• 4.3 Checking oil pressure and oil pressure switch
  229
• 4.4 Removing and installing oil filter housing
  229
• 4.5 Removing and installing oil pressure regulating valve N428
  230
• Cooling
  233
• 1 Cooling system/coolant
  233
• 1.1 Connection diagram - coolant hoses
  233
• 1.2 Checking cooling system for leaks
  234
• 1.3 Draining and adding coolant
  239
• 2 Coolant pump, regulation of cooling system
  254
• 2.1 Assembly overview - coolant pump, thermostat
  254
• 2.2 Assembly overview - electric coolant pump
  257
• 2.3 Assembly overview - coolant temperature sender
  258
• 2.4 Removing and installing electric coolant pump
  259
• 2.5 Removing and installing coolant pump
  262
• 2.6 Removing and installing thermostat
  267
• 2.7 Removing and installing toothed belt pulley for coolant pump
  271
• 2.8 Removing and installing coolant temperature sender G62
  272
• 2.9 Removing and installing radiator outlet coolant temperature sender G83
  275
• 3 Coolant pipes
  279
• 3.1 Assembly overview - coolant pipes
  279
• 3.2 Removing and installing coolant pipes
  279
• 4 Radiator, radiator fan
  282
• 4.1 Assembly overview - radiator/radiator fan
  282
• 4.2 Assembly overview - radiator cowl and radiator fan
  285
• 4.3 Assembly overview - radiator blind
  287
• 4.4 Removing and installing radiator
  290
• 4.5 Removing and installing water radiator for charge air cooling circuit
  296
• 4.6 Removing and installing radiator cowl
  301
• 4.7 Removing and installing radiator fan V7
  304
• 4.8 Removing and installing radiator blind
  306
• 4.9 Removing and installing radiator blind control motor V544
  308
• Fuel supply system
  314
• 1 Safety information
  314
• 1.1 Safety regulations for working on fuel supply
  314
• 1.3 Safety measures when working on vehicles with a start/stop system
  315
• 2 Identification
  316
• 2.1 Engine number/engine data
  316
• 3 General information
  317
• 4 Fuel
  318
• 4.1 Assembly overview - fuel tank
  318
• 4.2 Emptying fuel tank
  325
• 4.3 Removing and installing fuel tank
  336
• 5 Fuel delivery unit, fuel gauge sender
  348
• 5.1 Assembly overview - fuel delivery unit/fuel gauge sender
  348
• 5.2 Removing and installing fuel delivery unit, fuel gauge sender
  352
• 5.3 Removing and installing fuel gauge sender G
  365
• 6 Plug-in connectors
  369
• 6.1 Separating plug-in connectors
  369
• 7 Fuel filter
  375
• 7.1 Assembly overview - fuel filter
  375
• 7.2 Removing and installing fuel filter
  375
• 8 Activated charcoal filter system
  378
• 8.1 Assembly overview - activated charcoal filter system
  378
• 8.2 Removing and installing activated charcoal filter
  379
• 8.3 Checking fuel tank breather
  381
• 9 Accelerator pedal
  387
• 9.1 Assembly overview - accelerator module
  387
• 10 Fuel pump
  388
• 10.1 Checking fuel system pressurisation pump G6
  388
• Turbocharging/supercharging
  450
• 1 Exhaust turbocharger
  450
• 1.1 Assembly overview - turbocharger
  450
• 1.2 Removing and installing turbocharger
  453
• 1.3 Removing and installing charge pressure positioner V465
  459
• 1.4 Removing and installing connection for turbocharger
  460
• 2 Charge air system
  464
• 2.1 Assembly overview - charge air system
  464
• 2.2 Removing and installing charge air cooler
  466
• 2.3 Removing and installing charge pressure sender GX26
  468
• 2.4 Checking charge air system for leaks
  469
• 2.5 Removing and installing air pipe
  471
• Mixture preparation - injection
  473
• 1 Injection system
  473
• 1.1 Overview of fitting locations - injection system
  473
• 2 Injectors
  484
• 2.1 Assembly overview - fuel rail with injectors
  484
• 2.2 Removing and installing fuel rail
  485
• 2.3 Removing and installing injectors
  486
• 2.4 Cleaning injectors
  493
• 3 Air filter
  495
• 3.1 Assembly overview - air filter housing
  495
• 3.2 Removing and installing air filter housing
  498
• 4 Intake manifold
  500
• 4.1 Assembly overview - intake manifold
  500
• 4.2 Removing and installing intake manifold
  502
• 4.3 Removing and installing throttle valve module GX3
  505
• 4.4 Cleaning throttle valve module GX3
  507
• 5 Senders and sensors
  509
• 5.1 Removing and installing fuel pressure sender G247
  509
• 5.2 Checking fuel pressure sender G247
  510
• 5.3 Removing and installing intake manifold sender GX9
  513
• 6 Engine (motor) control unit
  514
• 6.1 Assembly overview - engine control unit
  514
• 6.2 Removing and installing engine (motor) control unit J623
  515
• 7 High-pressure pump
  521
• 7.1 Assembly overview - high-pressure pump
  521
• 7.2 Removing and installing high-pressure pump
  522
• 7.3 Removing and installing high-pressure pipe
  524
• 8 Lambda probe
  526
• 8.1 Assembly overview - Lambda probe
  526
• 8.2 Removing and installing Lambda probe
  527
• Exhaust system
  530
• 1 Exhaust pipes, silencers
  530
• 1.1 Assembly overview - silencers
  530
• 1.2 Separating exhaust pipes/silencers
  532
• 1.3 Removing and installing silencer
  534
• 1.4 Aligning exhaust system free of stress
  540
• 1.5 Check exhaust system for leaks
  541
• 1.6 Installation position of clamp
  542
• 2 Exhaust gas cleaning
  544
• 2.1 Assembly overview - emission control
  544
• 2.2 Removing and installing catalytic converter
  549
• Ignition system
  553
• 1 Ignition system
  553
• 1.1 Assembly overview - ignition system
  553
• 1.2 Removing and installing ignition coils with output stage
  555
• 1.3 Removing and installing knock sensor 1 G61
  558
• 1.4 Removing and installing Hall sender
  559
• 1.5 Removing and installing engine speed sender G28
  560