3-cylinder injection engine (1.0 l engine, 4 V, 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
• 2 Identification
  3
• 2.1 Engine number/engine data
  3
• 3 Repair instructions
  5
• 3.1 Rules for cleanliness
  5
• 3.2 Foreign objects in engine
  5
• 3.3 Contact corrosion
  5
• 3.4 Routing and attachment of lines
  5
• 3.5 Fitting radiator and condensers
  6
• Removing and installing engine
  7
• 1 Removing and installing engine
  7
• 1.1 Removing engine
  7
• 1.2 Separating engine and gearbox
  14
• 1.3 Securing engine on engine and gearbox support
  16
• 1.4 Installing engine
  18
• 2 Assembly mountings
  20
• 2.1 Assembly overview - assembly mountings
  20
• 2.2 Removing and installing engine mounting
  22
• 2.3 Removing and installing gearbox mounting
  22
• 2.4 Removing and installing pendulum support
  23
• 2.5 Supporting engine in installation position
  24
• 2.6 Adjusting assembly mountings
  35
• 2.7 Checking adjustment of assembly mountings
  35
• Crankshaft group
  36
• 1 Cylinder block (pulley end)
  36
• 1.1 Assembly overview - poly V-belt drive
  36
• 1.2 Assembly overview - cylinder block (pulley end)
  36
• 1.3 Removing and installing poly-V belt
  38
• 1.4 Removing and installing engine support
  41
• 1.5 Renewing crankshaft oil seal - belt pulley end
  43
• 2 Cylinder block, gearbox end
  46
• 2.1 Assembly overview - cylinder block, gearbox end
  46
• 2.2 Removing and installing flywheel
  47
• 2.3 Removing and installing sealing flange on gearbox side
  48
• 3 Crankshaft
  60
• 3.1 Crankshaft dimensions
  60
• 4 Pistons and conrods
  61
• 4.1 Assembly overview - pistons and conrods
  61
• 4.2 Checking pistons and cylinder bores
  63
• 4.3 Separating new conrod
  65
• 4.4 Setting piston to TDC position
  66
• Cylinder head, valve gear
  69
• 1 Cylinder head
  69
• 1.1 Assembly overview - cylinder head
  69
• 1.2 Removing and installing cylinder head
  72
• 1.3 Removing and installing camshaft housing
  78
• 1.4 Checking compression
  83
• 2 Toothed belt drive
  85
• 2.1 Assembly overview - toothed belt
  85
• 2.2 Removing and installing toothed belt
  87
• 2.3 Preassembling and installing valve timing tool
  108
• 2.4 Checking valve timing
  116
• 2.5 Adjusting valve timing
  120
• 2.6 Removing toothed belt from camshaft
  131
• 3 Valve gear
  138
• 3.1 Assembly overview - valve gear
  138
• 3.2 Measuring axial play of camshaft
  139
• 3.3 Removing and installing camshaft adjuster
  140
• 3.4 Removing and installing toothed belt pulley
  146
• 3.5 Removing and installing camshaft oil seal
  150
• 3.6 Removing and installing valve stem seals
  160
• 4 Inlet and exhaust valves
  171
• 4.1 Checking valve guides
  171
• Lubrication
  172
• 1 Sump, oil pump
  172
• 1.1 Assembly overview - sump/oil pump
  172
• 1.2 Engine oil:
  176
• 1.3 Removing and installing sump
  176
• 1.4 Removing and installing oil pump
  181
• 2 Crankcase ventilation
  184
• 2.1 Assembly overview - crankcase breather system
  184
• 2.2 Removing and installing oil separator
  185
• 3 Oil filter, oil pressure switch
  189
• 3.1 Removing and installing oil pressure switch F1
  189
• 3.2 Checking oil pressure and oil pressure switch
  190
• 3.3 Removing and installing oil filter housing
  192
• Cooling
  194
• 1 Cooling system/coolant
  194
• 1.1 Connection diagram - coolant hoses
  194
• 1.2 Checking cooling system for leaks
  194
• 1.3 Draining and adding coolant
  198
• 2 Coolant pump, regulation of cooling system
  206
• 2.1 Assembly overview - coolant pump
  206
• 2.2 Assembly overview - thermostat
  209
• 2.3 Removing and installing coolant pump
  212
• 2.4 Removing and installing thermostat
  217
• 2.5 Removing and installing toothed belt for coolant pump
  223
• 2.6 Removing and installing coolant temperature sender G62
  226
• 2.7 Removing and installing radiator fan thermal switch F18
  229
• 3 Radiator, radiator fan
  232
• 3.1 Assembly overview - radiator/radiator fan
  232
• 3.2 Removing and installing radiator
  234
• 3.3 Removing and installing radiator cowl with radiator fan
  239
• 3.4 Removing and installing radiator fan V7
  241
• Mixture preparation - injection
  245
• 1 Injection system
  245
• 1.1 Overview of fitting locations - injection system
  245
• 1.2 Assembly overview - fuel system
  248
• 2 Injectors
  251
• 2.1 Assembly overview - fuel rail with injectors
  251
• 2.2 Removing and installing injectors
  251
• 2.3 Checking injectors
  253
• 2.4 Cleaning injectors
  258
• 3 Air filter
  260
• 3.1 Assembly overview - air filter housing
  260
• 3.2 Removing and installing air filter housing
  260
• 4 Intake manifold
  262
• 4.1 Assembly overview – intake manifold
  262
• 4.2 Removing and installing intake manifold
  264
• 4.3 Removing and installing throttle valve module GX3
  267
• 4.4 Cleaning throttle valve module GX3
  269
• 5 Senders and sensors
  271
• 5.1 Removing and installing intake manifold sender GX9
  271
• 6 Engine control unit
  273
• 6.1 Assembly overview – motor control unit
  273
• 6.2 Removing and installing engine control unit J623
  274
• 6.3 Removing and installing engine (motor) control unit J623 with protective housing
  278
• 7 Lambda probe
  280
• 7.1 Assembly overview - Lambda probe
  280
• 7.2 Removing and installing Lambda probe
  284
• Exhaust system
  289
• 1 Exhaust pipes and silencers
  289
• 1.1 Assembly overview – silencers
  289
• 1.2 Separating exhaust pipes from silencers
  290
• 1.3 Removing and installing silencer
  291
• 1.4 Checking exhaust system for leaks
  293
• 1.5 Installation position of clamp
  294
• 2 Emission control
  296
• 2.1 Assembly overview – emission control
  296
• 2.2 Removing and installing catalytic converter
  299
• Ignition system
  303
• 1 Ignition system
  303
• 1.1 Assembly overview - ignition system
  303
• 1.2 Removing and installing ignition coils with output stage
  305
• 1.3 Removing and installing knock sensor 1 G61
  308
• 1.4 Removing and installing Hall sender
  309
• 1.5 Removing and installing engine speed sender G28
  310