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 the cooling system
  2
• 1.5 Safety precautions when working on ignition system
  2
• 1.6 Identification
  3
• 2 Repair notes
  4
• 2.1 Rules for cleanliness
  4
• 2.2 Foreign objects in engine
  4
• 2.3 Contact corrosion
  4
• 2.4 Pipe/wire routing and attachment
  4
• 2.5 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
  16
• 1.3 Securing engine on engine and gearbox support
  17
• 1.4 Installing engine
  19
• 2 Assembly mountings
  22
• 2.1 Assembly overview - assembly mountings
  22
• 2.2 Supporting engine in installation position
  24
• 2.3 Removing and installing motor mounting
  27
• 2.4 Removing and installing gearbox mounting
  29
• 2.5 Removing and installing pendulum support
  30
• 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
  36
• 1.3 Removing and installing tensioner for poly V-belt
  39
• 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
  43
• 2 Cylinder block, gearbox end
  46
• 2.1 Assembly overview - cylinder block, gearbox end
  46
• 2.2 Removing and installing flywheel
  47
• 2.3 Removing and installing sealing flange on gearbox side
  48
• 3 Crankshaft
  57
• 3.1 Crankshaft dimensions
  57
• 3.2 Measuring axial clearance of crankshaft
  57
• 3.3 Renewing needle bearing in crankshaft
  58
• 4 Pistons and conrods
  62
• 4.1 Assembly overview - pistons and conrods
  62
• 4.2 Separating new conrod
  64
• 4.3 Removing and installing pistons
  64
• 4.4 Removing and installing oil spray jets
  65
• 4.5 Checking pistons and cylinder bores
  66
• 4.6 Checking radial clearance of conrods
  67
• Cylinder head, valve gear
  69
• 1 Cylinder head
  69
• 1.1 Assembly overview - cylinder head
  69
• 1.2 Assembly overview - camshaft housing
  70
• 1.3 Removing and installing cylinder head
  72
• 1.4 Removing and installing camshaft housing
  76
• 1.5 Checking compression
  80
• 2 Toothed belt drive
  83
• 2.1 Assembly overview - toothed belt cover
  83
• 2.2 Assembly overview - toothed belt
  84
• 2.3 Checking valve timing
  85
• 2.4 Removing toothed belt from camshaft
  91
• 2.5 Removing and installing toothed belt
  103
• 3 Valve gear
  117
• 3.1 Assembly overview - valve gear
  117
• 3.2 Measuring axial play of camshaft
  119
• 3.3 Removing and installing camshaft adjuster
  120
• 3.4 Removing and installing toothed belt pulley
  123
• 3.5 Removing and installing camshaft oil seal
  125
• 3.6 Removing and installing camshaft control valve 1 N205
  130
• 3.7 Removing and installing valve stem seals
  131
• 4 Inlet and exhaust valves
  139
• 4.1 Checking valve guides
  139
• 4.2 Checking valves
  139
• 4.3 Valve dimensions
  140
• Lubrication
  141
• 1 Sump, oil pump
  141
• 1.1 Assembly overview - sump/oil pump
  141
• 1.2 Engine oil:
  145
• 1.3 Removing and installing oil sump
  145
• 1.4 Removing and installing oil pump
  149
• 1.5 Removing and installing oil level and oil temperature sender G266
  152
• 2 Engine oil cooler
  153
• 2.1 Assembly overview - engine oil cooler
  153
• 2.2 Removing and installing engine oil cooler
  153
• 3 Crankcase ventilation
  155
• 3.1 Assembly overview - crankcase breather system
  155
• 3.2 Removing and installing oil separator
  156
• 4 Oil filter, oil pressure switch
  159
• 4.1 Assembly overview - oil filter/oil pressure switch
  159
• 4.2 Removing and installing oil pressure switch for reduced oil pressure F378
  160
• 4.3 Checking oil pressure and oil pressure switch
  161
• 4.4 Removing and installing oil filter housing
  162
• Cooling
  164
• 1 Cooling system/coolant
  164
• 1.1 Connection diagram - coolant hoses
  164
• 1.2 Draining and adding coolant
  166
• 1.3 Checking cooling system for leaks
  171
• 2 Coolant pump, regulation of cooling system
  173
• 2.1 Assembly overview - coolant pump, thermostat
  173
• 2.2 Assembly overview - electric coolant pump
  175
• 2.3 Assembly overview - coolant temperature sender
  177
• 2.4 Removing and installing coolant pump
  178
• 2.5 Removing and installing toothed belt pulley for coolant pump
  182
• 2.6 Removing and installing thermostat
  183
• 2.7 Removing and installing electric coolant pump
  186
• 2.8 Removing and installing coolant temperature sender G62
  188
• 2.9 Removing and installing radiator fan thermal switch F18
  190
• 3 Coolant pipes
  192
• 3.1 Assembly overview - coolant pipes
  192
• 3.2 Removing and installing coolant pipes
  192
• 4 Radiator, radiator fan
  196
• 4.1 Assembly overview - radiator/radiator fan
  196
• 4.2 Assembly overview - radiator cowl and radiator fan
  198
• 4.3 Removing and installing radiator
  199
• 4.4 Removing and installing water radiator for charge air cooling circuit
  202
• 4.5 Removing and installing radiator cowl
  205
• 4.6 Removing and installing radiator fan V7
  207
• Turbocharging/supercharging
  209
• 1 Exhaust turbocharger
  209
• 1.1 Assembly overview - turbocharger
  209
• 1.2 Removing and installing turbocharger
  211
• 1.3 Removing and installing charge pressure positioner V465
  215
• 1.4 Removing and installing connection for turbocharger
  216
• 2 Charge air system
  220
• 2.1 Assembly overview - charge air system
  220
• 2.2 Removing and installing air pipe
  222
• 2.3 Removing and installing charge pressure sender GX26
  223
• 2.4 Removing and installing charge air cooler
  223
• 2.5 Checking charge air system for leaks
  226
• Mixture preparation - injection
  229
• 1 Injection system
  229
• 1.1 Overview of fitting locations - injection system
  229
• 2 Air filter
  233
• 2.1 Assembly overview - air filter housing
  233
• 2.2 Removing and installing air filter housing
  234
• 2.3 Removing and installing resonator for intake air
  235
• 3 Intake manifold
  236
• 3.1 Assembly overview - intake manifold
  236
• 3.2 Removing and installing intake manifold
  238
• 3.3 Removing and installing throttle valve module GX3
  240
• 3.4 Cleaning throttle valve module GX3
  241
• 4 Injectors
  243
• 4.1 Assembly overview - fuel rail with injectors
  243
• 4.2 Removing and installing fuel rail
  244
• 4.3 Removing and installing injectors
  245
• 5 Senders and sensors
  250
• 5.1 Removing and installing intake manifold sender GX9
  250
• 5.2 Removing and installing fuel pressure sender G247
  250
• 5.3 Checking fuel pressure sender G247
  251
• 6 High-pressure pump
  254
• 6.1 Assembly overview - high-pressure pump
  254
• 6.2 Removing and installing high-pressure pump
  255
• 6.3 Removing and installing high-pressure pipe
  256
• 7 Lambda probe
  258
• 7.1 Assembly overview - Lambda probe
  258
• 7.2 Removing and installing Lambda probe
  259
• 8 Engine (motor) control unit
  262
• 8.1 Assembly overview - engine control unit
  262
• 8.2 Removing and installing engine (motor) control unit J623
  263
• Exhaust system
  265
• 1 Exhaust pipes, silencers
  265
• 1.1 Assembly overview - silencers
  265
• 1.2 Separating exhaust pipes, silencers
  266
• 1.3 Removing and installing silencer
  268
• 1.4 Aligning exhaust system free of tension
  270
• 1.5 Check exhaust system for leaks
  270
• 1.6 Installation position of clamp
  271
• 2 Exhaust gas cleaning
  272
• 2.1 Assembly overview - emission control
  272
• 2.2 Removing and installing catalytic converter
  273
• Ignition system
  278
• 1 Ignition system
  278
• 1.1 Assembly overview - ignition system
  278
• 1.2 Test data, spark plugs
  279
• 1.3 Removing and installing ignition coils with output stage
  279
• 1.4 Removing and installing knock sensor 1 G61
  281
• 1.5 Removing and installing Hall sender G40
  281
• 1.6 Removing and installing engine speed sender G28
  282