3-cylinder injection engine (1.2 l engine, 2V and 4V, EA 111)

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Engine number
  1
• Removing and installing engine
  3
• 1 Removing and installing engine
  3
• 1.1 Removing
  4
• 1.2 Installing
  8
• 1.3 Specified torques
  9
• Crankshaft group
  11
• 1 Dismantling and assembling engine
  11
• 1.1 Assembly overview - part I, belt drive
  11
• 1.2 Assembly overview - part II, chain drive, engine codes AWY, BMD, BBM
  12
• 1.3 Assembly overview - part II, chain drive, engine codes AZQ, BME, BZG
  15
• 1.4 Removing and installing poly V-belt
  17
• 1.5 Removing and installing valve timing housing
  19
• 2 Cylinder block, seals
  24
• 2.1 Assembly overview
  24
• 2.2 Renewing crankshaft oil seal - belt pulley end
  25
• 2.3 Renewing crankshaft oil seal - flywheel end
  27
• Cylinder head, valve gear
  30
• 1 Cylinder head
  30
• 1.1 Assembly overview - engine codes AWY, BMD, BBM
  30
• 1.2 Removing and installing cylinder head, engine codes AWY, BMD, BBM
  32
• 1.3 Assembly overview - engine codes AZQ, BME, BZG
  35
• 1.4 Removing and installing cylinder head, engine codes AZQ, BME, BZG
  38
• 1.5 Removing and installing camshaft housing, engine codes AZQ, BME, BZG
  41
• 1.6 Checking valve timing, engine codes AWY, BMD, BBM
  45
• 1.7 Checking valve timing, engine codes AZQ, BME, BZG
  47
• 1.9 Adjusting valve timing, engine codes AWY, BMD, BBM
  51
• 1.11 Adjusting valve timing, engine codes AZQ, BME, BZG
  58
• 1.12 Checking compression
  61
• 2 Valve gear
  64
• 2.1 Assembly overview - engine codes AWY, BMD, BBM
  64
• 2.2 Assembly overview - engine codes AZQ, BME, BZG
  66
• 2.3 Checking camshaft axial clearance
  69
• 2.4 Reworking valve seats
  69
• 2.5 Checking valve guides
  72
• 2.6 Renewing valve stem seals
  73
• Lubrication
  77
• 1 Parts of lubrication system
  77
• 1.1 Engine oil
  77
• 1.2 Assembly overview
  77
• 1.3 Assembly overview - oil filter
  80
• 1.4 Removing and installing oil filter element
  80
• 1.5 Removing and installing oil sump
  81
• 1.6 Checking oil pressure and oil pressure switch
  82
• Cooling
  84
• 1 Parts of cooling system
  84
• 1.1 Assembly overview - parts of cooling system, body side (radiator with two fans)
  84
• 1.2 Assembly overview - parts of cooling system, body side (radiator with one fan)
  86
• 1.3 Assembly overview - parts of cooling system, engine side
  87
• 1.4 Draining and filling coolant
  88
• 1.5 Removing and installing radiator
  90
• 1.6 Removing and installing coolant pump
  92
• Fuel supply system
  94
• 1 Parts of fuel supply system
  94
• 1.1 Assembly overview - fuel tank with attachments
  94
• 1.2 Safety precautions when working on fuel supply system
  97
• 1.3 Rules for cleanliness
  98
• 1.4 Removing and installing fuel delivery unit
  98
• 1.5 Removing and installing fuel gauge sender G
  100
• 1.6 Removing and installing fuel tank
  100
• 1.7 Crash fuel shut-off
  102
• 1.8 Checking fuel pump
  102
• 1.9 Bleeding fuel system
  110
• 2 Activated charcoal filter system
  113
• 2.1 Function
  113
• 2.2 Assembly overview
  113
• 2.3 Checking fuel tank breather
  114
• 3 Electronic power control (EPC)
  116
• 3.1 Assembly overview
  116
• Mixture preparation - injection
  117
• 1 Injection system
  117
• 1.1 Assembly overview - parts of injection system
  117
• 1.2 Assembly overview - intake manifold, engine codes AWY, BMD, BBM
  119
• 1.3 Assembly overview - intake manifold, engine codes AZQ, BME, BZG
  120
• 1.4 Assembly overview - fuel rail with injectors, engine code AWY
  121
• 1.6 Assembly overview - air filter, engine codes AWY, AZQ, BME
  122
• 1.7 Removing and installing air filter, engine codes AWY, AZQ, BME
  123
• 1.8 Assembly overview - air filter, engine codes BMD, BBM, BZG
  124
• 1.9 Removing and installing air filter, engine codes BMD, BBM, BZG
  125
• 1.10 Cleaning throttle valve module J338
  126
• 1.11 Safety precautions
  127
• 1.12 Rules for cleanliness
  128
• 1.13 Technical data
  129
• 2 Checking components
  130
• 2.1 Checking injectors
  130
• 2.2 Checking fuel pressure regulator and holding pressure
  134
• 2.3 Checking intake air preheating
  137
• 2.4 Check non-return valve for crankcase breather
  137
• 3 Engine control unit J623
  140
• 3.1 Removing and installing engine control unit J623
  140
• 3.2 Removing and installing anti-theft-secured engine control unit J623 (►model year 2007)
  140
• 3.3 Vehicles with anti-theft secured engine control unit J623 (model year 2007►)
  142
• Exhaust system
  144
• 1 Parts of the exhaust system
  144
• 1.1 Assembly overview - front exhaust system with attachments
  144
• 1.2 Assembly overview - silencers with mountings
  145
• 2 Exhaust gas recirculation system
  147
• 2.1 Assembly overview
  147
• Ignition system
  148
• 1 Ignition system
  148
• 1.1 Assembly overview - parts of ignition system
  148
• 1.2 Removing and installing ignition coils with output stage
  149
• 1.3 Safety precautions
  150
• 1.4 Test data, spark plugs
  151