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
  4
• 3.1 Rules for cleanliness
  4
• 3.2 General information
  4
• 3.3 General repair instructions
  4
• 3.4 Foreign objects in engine
  5
• 3.5 Contact corrosion
  5
• 3.6 Routing and attachment of lines
  5
• 3.7 Fitting radiator and condensers
  5
• 3.8 Checking vacuum system
  5
• Removing and installing engine
  7
• 1 Removing and installing engine
  7
• 1.1 Removing engine
  7
• 1.2 Separating engine and gearbox
  24
• 1.3 Securing engine on engine and gearbox support
  25
• 1.4 Installing engine
  27
• 2 Assembly mountings
  32
• 2.1 Assembly overview - assembly mountings
  32
• 2.2 Removing and installing engine mounting
  36
• 2.3 Removing and installing gearbox mounting
  39
• 2.4 Removing and installing pendulum support
  43
• 2.5 Supporting engine in installation position
  45
• 2.6 Adjusting assembly mountings
  49
• 2.7 Checking adjustment of assembly mountings (engine and gearbox mountings)
  50
• Crankshaft group
  51
• 1 Cylinder block (pulley end)
  51
• 1.1 Assembly overview - poly V-belt drive
  51
• 1.2 Assembly overview - cylinder block (pulley end)
  55
• 1.3 Removing and installing poly-V belt
  57
• 1.4 Removing and installing tensioner for poly V-belt
  62
• 1.5 Removing and installing engine support
  65
• 1.6 Renewing crankshaft oil seal - belt pulley end
  67
• 2 Cylinder block, gearbox end
  70
• 2.1 Assembly overview - cylinder block, gearbox end
  70
• 2.2 Removing and installing flywheel
  71
• 2.3 Removing and installing sealing flange on gearbox side
  72
• 3 Crankshaft
  80
• 3.1 Crankshaft dimensions
  80
• 4 Pistons and conrods
  81
• 4.1 Assembly overview - pistons and conrods
  81
• 4.2 Checking pistons and cylinder bores
  82
• 4.3 Separating new conrod
  84
• 4.4 Removing and installing oil spray jets
  85
• 4.5 Setting piston to TDC position
  86
• Cylinder head, valve gear
  88
• 1 Cylinder head
  88
• 1.1 Assembly overview - cylinder head
  88
• 1.2 Removing and installing cylinder head
  91
• 1.3 Removing and installing camshaft housing
  97
• 1.4 Checking compression
  100
• 2 Toothed belt drive
  104
• 2.1 Assembly overview - toothed belt cover
  104
• 2.2 Assembly overview - toothed belt
  105
• 2.3 Removing and installing toothed belt guard
  106
• 2.4 Removing and installing toothed belt
  107
• 2.5 Preassembling and installing valve timing tool
  114
• 2.6 Checking valve timing
  121
• 2.7 Adjusting valve timing
  124
• 2.8 Removing toothed belt from camshaft
  133
• 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 oil seal
  140
• 3.4 Removing and installing camshaft adjuster
  144
• 3.5 Removing and installing toothed belt pulley
  149
• 3.6 Removing and installing valve stem seals
  152
• 4 Inlet and exhaust valves
  160
• 4.1 Checking valve guides
  160
• Lubrication
  161
• 1 Sump, oil pump
  161
• 1.1 Assembly overview - sump/oil pump
  161
• 1.2 Engine oil:
  164
• 1.3 Removing and installing sump
  165
• 1.4 Removing and installing oil pump
  168
• 1.5 Removing and installing oil level and oil temperature sender G266
  170
• 2 Crankcase ventilation
  171
• 2.1 Assembly overview - crankcase breather system
  171
• 2.2 Removing and installing oil separator
  172
• 3 Oil filter, oil pressure switch
  175
• 3.1 Removing and installing oil pressure switch F1
  175
• 3.2 Checking oil pressure and oil pressure switch
  176
• 3.3 Removing and installing oil filter housing
  177
• Cooling
  179
• 1 Cooling system/coolant
  179
• 1.1 Connection diagram - coolant hoses
  179
• 1.2 Checking cooling system for leaks
  180
• 1.3 Draining and adding coolant
  183
• 2 Coolant pump, regulation of cooling system
  197
• 2.1 Assembly overview - coolant pump
  197
• 2.2 Assembly overview - thermostat
  199
• 2.3 Removing and installing coolant pump
  201
• 2.4 Removing and installing thermostat
  205
• 2.5 Removing and installing toothed belt for coolant pump
  211
• 2.6 Removing and installing toothed belt pulley for coolant pump
  214
• 2.7 Removing and installing coolant temperature sender G62
  215
• 3 Coolant pipes
  217
• 3.1 Assembly overview - coolant pipes
  217
• 3.2 Removing and installing coolant pipes
  218
• 4 Radiator, radiator fan
  220
• 4.1 Assembly overview - radiator/radiator fan
  220
• 4.2 Assembly overview - radiator cowl and radiator fan
  223
• 4.3 Removing and installing radiator
  225
• 4.4 Removing and installing radiator cowl with radiator fan
  233
• 4.5 Removing and installing radiator fan V7
  235
• Mixture preparation - injection
  237
• 1 Injection system
  237
• 1.1 Overview of fitting locations - injection system
  237
• 1.2 Assembly overview - fuel system
  244
• 2 Injectors
  246
• 2.1 Assembly overview - fuel rail with injectors
  246
• 2.2 Removing and installing injectors
  246
• 2.3 Checking injectors
  248
• 2.4 Cleaning injectors
  253
• 3 Air filter
  255
• 3.1 Assembly overview - air filter housing
  255
• 3.2 Removing and installing air filter housing
  258
• 4 Intake manifold
  260
• 4.1 Assembly overview - intake manifold
  260
• 4.2 Removing and installing intake manifold
  261
• 4.3 Removing and installing throttle valve module GX3
  263
• 4.4 Cleaning throttle valve module GX3
  265
• 5 Senders and sensors
  266
• 5.1 Removing and installing intake manifold sender GX9
  266
• 6 Engine control unit
  268
• 6.1 Assembly overview - engine control unit
  268
• 6.2 Removing and installing engine (motor) control unit J623
  269
• 7 Lambda probe
  276
• 7.1 Assembly overview - Lambda probe
  276
• 7.2 Removing and installing Lambda probe
  277
• Exhaust system
  284
• 1 Exhaust pipes and silencers
  284
• 1.1 Assembly overview - silencers
  284
• 1.2 Separating exhaust pipes from silencers
  287
• 1.3 Removing and installing silencer
  288
• 1.4 Aligning exhaust system free of stress
  291
• 1.5 Checking exhaust system for leaks
  291
• 1.6 Installation position of clamp
  292
• 2 Emission control
  294
• 2.1 Assembly overview - emission control
  294
• 2.2 Removing and installing catalytic converter
  297
• 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
  307
• 1.4 Removing and installing Hall sender G40
  308
• 1.5 Removing and installing engine speed sender G28
  309