4-Cyl. injection engine (1.4 l)

Chapter overview

• Technical data
  1
• 1 \--- Change history ---
  1
• 2 Identification
  2
• 2.1 Engine number/engine characteristics
  2
• 3 Safety indications
  4
• 3.1 Safety measures for working on fuel supply system
  4
• 3.2 Safety measures for work in vehicles with Start-Stop system
  4
• 3.3 Safety measures for test drives with testing and measuring equipment
  4
• 3.4 Safety measures when working on the cooling system
  5
• 3.5 Safety measures when working on the ignition system
  5
• 4 Repair instructions
  6
• 4.1 Cleanliness rules
  6
• 4.2 Foreign bodies on the engine
  6
• 4.3 Contact corrosion
  6
• 4.4 Cable routing and fastening
  6
• 4.5 Radiators and condensers - assembly
  7
• Removing and installing engine
  8
• 1 Engine - remove and install
  8
• 1.1 Engine - removal
  8
• 1.2 Engine and gearbox - separate
  21
• 1.3 Engine in the gearbox and engine support - secure
  25
• 1.4 Engine - install
  26
• 2 Assembly mountings
  30
• 2.1 Assembly mountings - assembly overview
  30
• 2.2 Hold the engine in assembly position
  35
• 2.3 Engine bracket - remove and install
  40
• 2.4 Gearbox bracket - remove and install
  42
• 2.5 Pendulum support (torque limiter) - remove and install
  44
• 2.6 Assembly mountings adjustment - check
  45
• 2.7 Assembly mountings - adjust
  46
• Crankshaft group
  49
• 1 Cylinder block - belt pulley side
  49
• 1.1 Poly-V belt drive - assembly overview
  49
• 1.2 Pulley side sealing flange - assembly overview
  51
• 1.3 Poly-V belt - remove and install
  53
• 1.4 Poly-V belt tensioner - remove and install
  55
• 1.5 Pulley (vibration damper) - remove and install
  56
• 1.6 Engine console - remove and install
  57
• 1.7 Crankshaft seal on the pulley side - replace
  62
• 1.8 Sealing flange on the belt pulley side - remove and install
  64
• 2 Cylinder block, gearbox side
  68
• 2.1 Cylinder block (gearbox side) - assembly overview
  68
• 2.2 Clutch Disk - removal and installation
  70
• 2.3 Sealing flange on the gearbox side - remove and install
  73
• 3 Crankshaft
  86
• 3.1 Crankshaft - dimensions
  86
• 3.2 Crankshaft axial clearance - measure
  86
• 4 Piston and connecting rod
  88
• 4.1 Piston and connecting rod - assembly overview
  88
• 4.2 Pistons - remove and install
  92
• 4.3 Oil injectors - remove and install
  93
• 4.4 Piston and cylinder - test
  94
• 4.5 Conrod radial clearance - check
  96
• Cylinder head, valve gear
  98
• 1 Toothed belt drive
  98
• 1.1 Toothed belt cover - assembly overview
  98
• 1.2 Toothed belt - assembly overview
  99
• 1.3 Toothed belt guard - remove and install
  101
• 1.4 Valve timing - check
  102
• 1.5 Remove the camshaft toothed belt
  108
• 1.6 Valve timing - adjust
  115
• 1.7 Toothed belt - remove and install
  123
• 2 Engine cylinder head
  130
• 2.1 Engine cylinder head - assembly overview
  130
• 2.2 Cylinder head cover with camshafts - assembly overview
  132
• 2.3 Engine cylinder head - remove and install
  135
• 2.4 Cylinder head cover with camshafts - remove and install
  140
• 2.5 Compression pressure - check
  145
• 3 Valve gear
  147
• 3.1 Valve gear - assembly overview
  147
• 3.2 Camshaft adjustment valve 1 N205 - remove and install
  149
• 3.3 Exhaust camshaft adjustment valve 1 N318 - remove and install
  149
• 3.4 Camshaft control shaft adjuster - remove and install
  150
• 3.5 Camshaft axial clearance - measure
  151
• 3.6 Camshaft seal - remove and install
  152
• 3.7 Valve stem sealant - remove and install
  158
• 4 Inlet and exhaust valves
  169
• 4.1 Valve guides - check
  169
• 4.2 Valves - check
  170
• 4.3 Valve dimensions
  170
• Lubrication
  171
• 1 Crankcase/oil pump
  171
• 1.1 Crankcase/oil pump - assembly overview
  171
• 1.2 Sump (bottom section) - remove and install
  175
• 1.3 Oil pump - remove and install
  180
• 1.4 Sump (top section) - remove and install
  182
• 1.5 Engine oil
  188
• 2 Engine oil cooler
  189
• 2.1 Engine oil cooler - assembly overview
  189
• 2.2 Engine oil cooler - remove and install
  189
• 3 Crankcase breather
  191
• 3.1 Crankcase breather - assembly overview
  191
• 3.2 Oil separator - remove and install
  192
• 4 Oil filter/Oil pressure switch
  195
• 4.1 Oil filter/Oil pressure switch - assembly overview
  195
• 4.2 Oil pressure switch F1 - remove and install
  196
• 4.3 Oil pressure switch F378 – remove and install
  197
• 4.4 Oil pressure control valve N428 - remove and install
  198
• 4.5 Oil pressure - check
  199
• Cooling
  202
• 1 Cooling system/coolant
  202
• 1.1 Coolant lines - connection diagram
  202
• 1.2 Coolant - drain and fill
  204
• 1.3 Cooling system - check tightness
  211
• 2 Coolant pump/coolant thermostat
  214
• 2.1 Coolant pump/coolant thermostat - assembly overview
  214
• 2.2 Air intake cooling pump - assembly overview
  217
• 2.3 Coolant temperature sensor - assembly overview
  218
• 2.4 Coolant pump - remove and install
  219
• 2.5 Coolant pump toothed belt roller - remove and install
  225
• 2.6 Coolant thermostat - remove and install
  226
• 2.7 Air intake cooling pump - remove and install
  230
• 2.8 Coolant temperature sensor G62 - remove and install
  232
• 2.9 radiator outlet coolant temperature sender G83 remove and install
  233
• 3 Coolant lines
  235
• 3.1 Coolant lines - assembly overview
  235
• 3.2 Coolant lines - remove and install
  235
• 4 Radiator/Radiator fan
  240
• 4.1 Radiator - assembly overview
  240
• 4.2 Fan cowl and radiator fan - assembly overview
  242
• 4.3 Radiator - remove and install
  243
• 4.4 Fan housing - remove and install
  245
• 4.5 Radiator fan V7 - remove and install
  246
• 4.6 Charge air cooling system radiator - remove and install
  247
• Fuel supply system
  251
• 1 Fuel tank
  251
• 1.1 Fuel tank - assembly overview
  251
• 1.2 Fuel tank - remove and install
  253
• 1.3 Fuel tank - drain
  260
• 2 Fuel supply unit/Fuel level sensor
  271
• 2.1 Fuel pump (pre-supply pump) G6/Fuel gauge sensor G - assembly overview
  271
• 2.2 Fuel pump (pre-supply pump) G6/Fuel gauge sensor G - remove and install
  273
• 2.3 Fuel gauge sensor G - remove and install
  278
• 2.4 Installation opening cover - remove and install
  279
• 3 Plug-in connectors
  281
• 3.1 Plug-in connectors - disconnect
  281
• 4 Fuel filter
  287
• 4.1 Fuel filter - remove and install
  287
• 5 Activated charcoal system
  289
• 5.1 Activated charcoal filter system - assembly overview
  289
• 5.2 Activated charcoal filter - remove and install
  290
• 5.3 Fuel tank ventilation - check
  291
• 6 Accelerator activation
  298
• 6.1 Accelerator pedal module - assembly overview
  298
• 6.2 Accelerator pedal module GX2 - remove and install
  298
• 7 Fuel system pressurisation pump G6
  300
• 7.1 Fuel system pressurisation pump G6 - check
  300
• 7.2 Fuel pump control unit J538 - remove and install
  319
• 8 Fuel lines
  321
• 8.1 Fuel lines - remove and install
  321
• Turbocharging/supercharging
  326
• 1 Turbocharger
  326
• 1.1 Turbocharger - assembly overview
  326
• 1.2 Turbocharger - remove and install
  330
• 1.3 Load pressure control V465 - remove and install
  334
• 1.4 Turbocharger inlet nozzle - remove and install
  336
• 2 Supercharging air system
  338
• 2.1 Supercharging air system - assembly overview
  338
• 2.2 Load pressure sensor GX26 - remove and install
  341
• 2.3 Intercooler - remove and install
  342
• 2.4 Charge air system - check air-tightness
  345
• 2.5 Air duct - remove and install
  347
• Mixture preparation - injection
  350
• 1 Injection system
  350
• 1.1 Injection system - assembly overview
  350
• 1.2 High fuel pressure - relieve
  354
• 2 Air cleaner
  356
• 2.1 Air filter - assembly overview
  356
• 2.2 Air filter - remove and install
  358
• 2.3 Air duct - remove and install
  359
• 3 Intake manifold
  361
• 3.1 Intake manifold - assembly overview
  361
• 3.2 Intake manifold - remove and install
  364
• 3.3 Throttle butterfly valve control unit GX3 - remove and install
  366
• 3.4 Throttle valve control unit GX3 - clean
  367
• 4 Injection valves
  369
• 4.1 Fuel rail with injection valves - assembly overview
  369
• 4.2 Fuel distributor - removal and installation
  371
• 4.3 Injection valves - remove and install
  372
• 4.4 Injectors - clean
  378
• 5 Transmitters and sensors
  380
• 5.1 Intake manifold sensor GX9 - remove and install
  380
• 5.2 Fuel pressure sensor G247 - remove and install
  381
• 5.3 Fuel pressure sensor G247 - check
  382
• 5.4 Ethanol concentration sensor G708
  384
• 5.5 Control unit and actuator for structure-borne sound – assembly overview
  388
• 6 High pressure pump
  390
• 6.1 High pressure pump - assembly overview
  390
• 6.2 High pressure pump - remove and install
  391
• 6.3 Rigid high pressure line - remove and install
  392
• 7 Lambda probe
  395
• 7.1 Lambda probe - assembly overview
  395
• 7.2 Lambda probe - remove and install
  396
• 8 Engine control unit
  400
• 8.1 Engine control unit J623 - remove and install
  400
• Exhaust system
  402
• 1 Silencer/exhaust pipes
  402
• 1.1 Silencer - assembly overview
  402
• 1.2 Silencer/exhaust pipes - detach
  404
• 1.3 Centre silencer with rear silencer - remove and install
  406
• 1.4 Centre silencer - remove and install
  410
• 1.5 Rear silencer - remove and install
  412
• 1.6 Exhaust system - tension free alignment
  413
• 1.7 Exhaust tail pipe - align
  413
• 1.8 Exhaust system - check tightness
  414
• 1.9 Pipe clamp installation position
  414
• 2 Emission control
  416
• 2.1 Emission control - assembly overview
  416
• 2.2 Catalytic converter - remove and install
  419
• Ignition system
  424
• 1 Ignition system
  424
• 1.1 Ignition system - assembly overview
  424
• 1.2 Test data, spark plugs
  426
• 1.3 Ignition coil with final power stage - remove and install
  426
• 1.4 Knock sensor 1 G61 - remove and install
  429
• 1.5 Hall Sensor - remove and install
  430
• 1.6 Engine speed sensor G28 - remove and install
  431