4-Cyl. injection engine (1.6 l) EA211

Chapter overview

• Technical data
  1
• 1 \--- Change history ---
  1
• 2 Safety instructions
  2
• 2.1 Safety measures regarding work on the fuel supply
  2
• 2.2 Safety measures in test drives using testing and measurement devices
  3
• 2.3 Safety measures when working on the cooling system
  4
• 2.4 Safety measures when working on the ignition system
  4
• 3 Identification
  6
• 3.1 Engine number/engine characteristics
  6
• 4 Repair instructions
  8
• 4.1 Cleaning rules
  8
• 4.2 Foreign bodies on the engine
  8
• 4.3 Contact corrosion
  8
• 4.4 Connection installation and fastening
  8
• 4.5 Radiator and capacitor installation
  9
• Removing and installing engine
  10
• 1 Engine - remove and install
  10
• 1.1 Engine - removal
  10
• 1.2 Engine - separate gearbox
  19
• 1.3 Secure the engine to the engine and gearbox swivelling stand
  21
• 1.4 Engine - installation
  22
• 2 Power-drive unit supports
  25
• 2.1 Power unit brackets - assembly overview
  25
• 2.2 Power-drive unit supports (engine side) - remove and install
  27
• 2.3 Power-drive unit supports (gearbox side) - remove and install
  29
• 2.4 Pendulum support (torque limiter) - remove and install
  32
• 2.5 Additional notes and installation works in vehicles with air conditioning
  33
• Crankshaft group
  34
• 1 Cylinder block (pulley side)
  34
• 1.1 Poly-V belt - assembly overview
  34
• 1.2 Poly-V belt - remove and install
  36
• 1.3 Poly-V belt tensioner - remove and install
  39
• 1.4 Crankshaft pulley (vibration damper) - remove and install
  40
• 1.5 Engine console - remove and install
  41
• 1.6 Crankshaft seal (pulley side) - replace
  43
• 2 Cylinder block (gearbox side)
  47
• 2.1 Cylinder block (gearbox side) - assembly overview
  47
• 2.2 Flywheel - remove and install
  48
• 2.3 Crankshaft flange (flywheel side) - replace
  49
• 3 Crankshaft
  62
• 3.1 Crankshaft dimensions
  62
• 3.2 Crankshaft - check axial clearance
  62
• 4 Pistons and conrods
  64
• 4.1 Pistons and conrods - assembly overview
  64
• 4.2 Pistons - remove and install
  68
• 4.3 Pistons, rings, and cylinders - check (conrod with bushing)
  69
• 4.4 Pistons, rings, and cylinders - check (conrod without bushing)
  71
• 4.5 Connecting rod (radial clearance) - check
  74
• 4.6 Oil injectors - remove and install
  74
• Cylinder head, valve gear
  76
• 1 Engine cylinder head
  76
• 1.1 Engine cylinder head - assembly overview
  76
• 1.2 Cylinder head cover with camshafts - assembly overview
  78
• 1.3 Engine cylinder head - remove and install
  81
• 1.4 Cylinder head cover with camshafts - remove and install
  88
• 1.5 Compression - check
  91
• 2 Toothed belt drive
  95
• 2.2 Toothed belt - assembly overview
  96
• 2.3 Mechanical distribution cover - removal and installation
  98
• 2.4 Valve timing - check
  99
• 2.5 Remove the toothed belt from the camshafts
  106
• 2.6 Toothed belt - remove and install
  116
• 3 Camshaft mechanism - repair
  124
• 3.1 Camshaft mechanism - assembly overview
  124
• 3.2 Crankshaft - check axial clearance
  126
• 3.3 Inlet camshaft regulator - remove and install
  127
• 3.4 Exhaust camshaft sprocket - remove and install
  133
• 3.5 Camshaft seal - replace
  138
• 3.6 Camshaft adjustment valve 1 N205 - remove and install
  145
• 3.7 Valve stem sealant - replace
  145
• 4 Inlet and exhaust valves
  156
• 4.1 Valve guides - check
  156
• 4.2 Valves - check
  157
• 4.3 Valves - dimensions
  157
• Lubrication
  158
• 1 Crankcase/oil pump
  158
• 1.1 Crankcase/oil pump - assembly overview
  158
• 1.2 Lower sump - remove and install
  161
• 1.3 Upper crankcase - remove and install
  164
• 1.4 Oil pump - remove and install
  168
• 1.5 Engine oil
  171
• 2 Engine oil cooler
  172
• 2.1 Engine oil cooler - assembly overview
  172
• 2.2 Engine oil cooler - remove and install
  172
• 3 Engine crankcase ventilation
  174
• 3.1 Engine crankcase ventilation - assembly overview
  174
• 3.2 Crankcase ventilation device - remove and install
  175
• 4 Oil filter/Oil pressure switch F1
  178
• 4.1 Oil filter/Oil pressure switch F1 - assembly overview
  178
• 4.2 Oil pressure switch 0.3...0.6 bar F1 - remove and install
  178
• 4.3 Oil filter - remove and install
  180
• 4.4 Oil pressure and Oil pressure switch F1 - check
  181
• Cooling
  184
• 1 Cooling system components
  184
• 1.1 Cooling system - assembly overview
  184
• 1.2 Hose connection diagram for cooling system
  186
• 1.3 Cooling system - drainage and replenishment
  187
• 1.4 Cooling system - check air-tightness
  196
• 1.5 Coolant tank flap - check safety valve
  198
• 2 Coolant/cooling system water pump
  200
• 2.1 Water pump - assembly overview
  200
• 2.2 Water pump - remove and install
  203
• 2.3 Water pump sprocket - remove and install
  209
• 2.4 Thermostat valve - remove and install
  210
• 2.5 Water pump toothed belt - remove and install
  218
• 2.6 Coolant temperature sensor G62 - remove and install
  221
• 3 Radiator
  224
• 3.1 Radiator - remove and install
  224
• 3.2 Cowling with Radiator fan V7 - remove and install
  227
• 3.3 Radiator fan V7 - remove and install
  227
• Fuel supply system
  228
• 1 Fuel supply system components
  228
• 1.1 Fuel tank - assembly overview
  228
• 1.2 Safety measures regarding work on the fuel supply
  232
• 1.3 Cleaning rules
  232
• 1.4 Cold start system components - remove and install
  233
• 1.5 Fuel pump (pre-supply pump) G6 - remove and install
  234
• 1.6 Fuel gauge sensor G - remove and install
  238
• 1.7 Fuel tank - remove and install
  238
• 1.8 Fuel shutoff in case of crash
  240
• 1.9 Fuel pump (pre-supply pump) G6 - check
  241
• 2 Engine power electronic adjustment (electronic accelerator)
  254
• 2.1 Engine power electronic adjustment (electronic accelerator) - assembly overview
  254
• 2.2 Electronic accelerator system operation
  254
• 3 Activated charcoal filter system
  256
• 3.1 Operation
  256
• 3.2 Activated charcoal filter system components - repair
  256
• 3.3 Fuel tank ventilation - check
  258
• Mixture preparation - injection
  260
• 1 Injection system
  260
• 1.1 Sensors, switches (intake side) - assembly overview
  260
• 1.2 Sensor, ignition coils and lambda probe (exhaust side) - assembly overview
  261
• 1.3 Injection system - assembly overview
  262
• 2 Injection valves
  267
• 2.1 Fuel rail with injection valves - assembly overview
  267
• 2.2 Injection valves - remove and install
  270
• 2.3 Injection valves - check
  274
• 3 Air cleaner
  279
• 3.1 Air filter - assembly overview
  279
• 3.2 Air filter - remove and install
  280
• 4 Intake manifold
  281
• 4.1 Intake manifold - assembly overview
  281
• 4.2 Intake manifold - remove and install
  282
• 4.3 Throttle butterfly valve control unit J338 - remove and install
  286
• 4.4 Throttle valve control unit J338 - clean
  287
• 4.5 Supply system pressure, fuel pressure gauge and residual pressure - check
  288
• 5 READINESS code
  296
• 5.1 Function
  296
• 5.2 Creating and Interpreting the READINESS code
  296
• 6 Transmitters and sensors
  297
• 7 Engine control unit J623
  299
• 7.1 Engine control unit J623 - remove and install
  299
• 8 Lambda probe
  303
• 8.1 Lambda probe - assembly overview
  303
• 8.2 Lambda probe - remove and install
  304
• Exhaust system
  308
• 1 Exhaust pipes/silencers
  308
• 1.1 Exhaust pipes/silencers - exploded view
  308
• 1.2 Separate exhaust pipes/silencers
  309
• 1.3 Silencers - remove and install
  310
• 1.4 Exhaust system - free of stress alignment
  311
• 1.5 Exhaust system - check air-tightness
  311
• 1.6 Pipe clamp installation position
  312
• 2 Exhaust gas purging
  313
• 2.1 Front exhaust pipe with catalytic converters - assembly overview
  313
• 2.2 Front exhaust pipe with catalytic converters - remove and install
  315
• Ignition system
  318
• 1 Ignition system
  318
• 1.1 Ignition system - assembly overview
  318
• 1.2 Ignition coils with final power stage - assembly overview
  320
• 1.3 Test data, spark plugs
  321
• 1.4 Ignition coil with final power stage - remove and install
  321
• 1.5 Knock sensor 1 G61 - remove and install
  324
• 1.6 Hall Sensor G40 - remove and install
  326
• 1.7 Engine speed sensor G28 - remove and install
  327