4-cyl. direct injection (1.2 l, 4V, EA 211, turbocharger)

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 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 notes
  4
• 3.1 Rules for cleanliness
  4
• 3.2 Foreign objects in engine
  4
• 3.3 Contact corrosion
  4
• 3.4 Routing and attachment of lines
  4
• 3.5 Fitting radiator and condensers
  5
• Removing and installing engine
  6
• 1 Removing and installing engine
  6
• 1.1 Removing engine
  6
• 1.2 Separating engine and gearbox
  15
• 1.3 Securing engine on engine and gearbox support
  16
• 1.4 Installing engine
  18
• 2 Assembly mountings
  21
• 2.1 Assembly overview - assembly mountings
  21
• 2.2 Removing and installing motor mounting
  23
• 2.3 Removing and installing gearbox mounting
  25
• 2.4 Removing and installing pendulum support
  26
• 2.5 Supporting engine in installation position
  26
• 2.6 Adjusting assembly mountings
  30
• 2.7 Checking adjustment of assembly mountings (engine and gearbox mountings)
  31
• Crankshaft group
  32
• 1 Cylinder block (pulley end)
  32
• 1.1 Assembly overview - poly V-belt drive
  32
• 1.2 Removing and installing poly-V belt
  35
• 1.3 Removing and installing tensioner for poly V-belt
  38
• 1.4 Removing and installing vibration damper
  39
• 1.5 Removing and installing engine support
  40
• 1.6 Renewing crankshaft oil seal - belt pulley end
  42
• 2 Cylinder block, gearbox end
  45
• 2.1 Assembly overview - cylinder block, gearbox end
  45
• 2.2 Removing and installing flywheel
  46
• 2.3 Removing and installing sealing flange on gearbox side
  47
• 3 Crankshaft
  55
• 3.1 Renewing needle bearing in crankshaft
  55
• 3.2 Crankshaft dimensions
  57
• 3.3 Measuring axial clearance of crankshaft
  58
• 4 Pistons and conrods
  59
• 4.1 Assembly overview - pistons and conrods
  59
• 4.2 Removing and installing pistons
  61
• 4.3 Checking pistons and cylinder bores
  62
• 4.4 Separating new conrod
  63
• 4.5 Checking radial clearance of conrods
  64
• 4.6 Removing and installing oil spray jets
  64
• Cylinder head, valve gear
  66
• 1 Cylinder head
  66
• 1.1 Assembly overview - cylinder head
  66
• 1.2 Assembly overview - camshaft housing
  68
• 1.3 Removing and installing cylinder head
  69
• 1.4 Removing and installing camshaft housing
  73
• 1.5 Checking compression
  76
• 2 Toothed belt drive
  79
• 2.1 Assembly overview - toothed belt cover
  79
• 2.2 Assembly overview - toothed belt
  80
• 2.3 Checking valve timing
  81
• 2.4 Removing toothed belt from camshaft
  87
• 2.5 Removing and installing toothed belt
  92
• 3 Valve gear
  99
• 3.1 Assembly overview - valve gear
  99
• 3.2 Measuring axial play of camshaft
  101
• 3.3 Removing and installing camshaft adjuster
  102
• 3.4 Removing and installing toothed belt pulley
  105
• 3.5 Removing and installing camshaft oil seal
  107
• 3.6 Removing and installing camshaft control valve 1 N205
  113
• 3.7 Removing and installing valve stem seals
  114
• 4 Inlet and exhaust valves
  123
• 4.1 Checking valve guides
  123
• 4.2 Checking valves
  123
• 4.3 Valve dimensions
  124
• Lubrication
  125
• 1 Sump, oil pump
  125
• 1.1 Assembly overview - sump/oil pump
  125
• 1.2 Engine oil:
  129
• 1.3 Removing and installing oil sump
  130
• 1.4 Removing and installing oil pump
  135
• 1.5 Removing and installing oil level and oil temperature sender G266
  138
• 2 Engine oil cooler
  139
• 2.1 Assembly overview - engine oil cooler
  139
• 2.2 Removing and installing engine oil cooler
  139
• 3 Crankcase ventilation
  141
• 3.1 Assembly overview - crankcase breather system
  141
• 3.2 Removing and installing oil separator
  142
• 4 Oil filter, oil pressure switch
  145
• 4.1 Assembly overview - oil filter/oil pressure switch
  145
• 4.2 Removing and installing oil pressure switch for reduced oil pressure F378
  145
• 4.3 Checking oil pressure and oil pressure switch
  146
• 4.4 Removing and installing oil filter housing
  147
• Cooling
  149
• 1 Cooling system/coolant
  149
• 1.1 Connection diagram - coolant hoses
  149
• 1.2 Checking cooling system for leaks
  150
• 1.3 Draining and adding coolant
  151
• 2 Coolant pump, regulation of cooling system
  158
• 2.1 Assembly overview - coolant pump, thermostat
  158
• 2.2 Assembly overview - charge air cooling pump V188
  161
• 2.3 Assembly overview - coolant temperature sender
  162
• 2.4 Removing and installing charge air cooling pump V188
  162
• 2.5 Removing and installing coolant pump
  164
• 2.6 Removing and installing thermostat
  169
• 2.7 Removing and installing toothed belt pulley for coolant pump
  173
• 2.8 Removing and installing coolant temperature sender G62
  174
• 2.9 Removing and installing radiator outlet coolant temperature sender G83
  175
• 3 Coolant pipes
  177
• 3.1 Assembly overview - coolant pipes
  177
• 3.2 Removing and installing coolant pipes
  177
• 4 Radiator, radiator fan
  181
• 4.1 Assembly overview - radiator/radiator fan
  181
• 4.2 Assembly overview - radiator cowl and radiator fan
  183
• 4.3 Removing and installing radiator
  183
• 4.4 Removing and installing water radiator for charge air cooling circuit
  184
• 4.5 Removing and installing radiator cowl
  187
• 4.6 Removing and installing radiator fan
  189
• Turbocharging/supercharging
  190
• 1 Exhaust turbocharger
  190
• 1.1 Assembly overview - turbocharger
  190
• 1.2 Removing and installing turbocharger
  192
• 1.3 Removing and installing charge pressure positioner V465
  195
• 2 Charge air system
  197
• 2.1 Assembly overview - charge air system
  197
• 2.2 Removing and installing charge air cooler
  199
• 2.3 Removing and installing charge pressure sender GX26
  201
• 2.4 Checking charge air system for leaks
  202
• 2.5 Removing and installing air pipe
  204
• Mixture preparation - injection
  207
• 1 Injection system
  207
• 1.1 Overview of fitting locations - injection system
  207
• 2 Injectors
  211
• 2.1 Assembly overview - fuel rail with injectors
  211
• 2.2 Removing and installing fuel rail
  212
• 2.3 Removing and installing injectors
  213
• 2.4 Cleaning injectors
  222
• 3 Air filter
  224
• 3.1 Assembly overview - air filter housing
  224
• 3.2 Removing and installing air filter housing
  225
• 3.3 Removing and installing resonator for intake air
  226
• 4 Intake manifold
  227
• 4.1 Assembly overview - intake manifold
  227
• 4.2 Removing and installing intake manifold
  228
• 4.3 Removing and installing throttle valve module GX3
  230
• 4.4 Cleaning throttle valve module GX3
  231
• 5 Senders and sensors
  233
• 5.1 Removing and installing intake manifold sender GX9
  233
• 5.2 Removing and installing fuel pressure sender G247
  233
• 5.3 Checking fuel pressure sender G247
  234
• 6 Engine (motor) control unit
  237
• 6.1 Removing and installing engine (motor) control unit J623
  237
• 7 High-pressure pump
  242
• 7.1 Assembly overview - high-pressure pump
  242
• 7.2 Removing and installing high-pressure pump
  244
• 7.3 Removing and installing high-pressure pipe
  245
• 8 Lambda probe
  247
• 8.1 Assembly overview - Lambda probe
  247
• 8.2 Removing and installing Lambda probe
  248
• Exhaust system
  251
• 1 Exhaust pipes, silencers
  251
• 1.1 Assembly overview - silencers
  251
• 1.2 Separating exhaust pipes, silencers
  252
• 1.3 Removing and installing silencer
  254
• 1.4 Aligning exhaust system free of stress
  255
• 1.5 Check exhaust system for leaks
  257
• 1.6 Installation position of clamp
  257
• 2 Exhaust gas cleaning
  259
• 2.1 Assembly overview - emission control
  259
• 2.2 Removing and installing catalytic converter
  260
• Ignition system
  264
• 1 Ignition system
  264
• 1.1 Assembly overview - ignition system
  264
• 1.2 Test data, spark plugs
  265
• 1.3 Removing and installing ignition coils with output stage
  265
• 1.4 Removing and installing knock sensor 1 G61
  268
• 1.5 Removing and installing Hall sender G40
  268
• 1.6 Removing and installing engine speed sender G28
  268