4-cyl. direct injection (1.4 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
• 2 Identification
  3
• 2.1 Engine number/engine data
  3
• 3 Repair instructions
  5
• 3.1 Rules for cleanliness
  5
• 3.2 Foreign objects in engine
  5
• 3.3 Contact corrosion
  5
• 3.4 Routing and attachment of lines
  5
• 3.5 Fitting radiator and condensers
  6
• Removing and installing engine
  7
• 1 Removing and installing motor
  7
• 1.1 Removing motor
  7
• 1.2 Separating engine and gearbox
  19
• 1.3 Securing engine on engine and gearbox support
  21
• 1.4 Installing engine
  22
• 2 Assembly mountings
  25
• 2.1 Assembly overview - assembly mountings
  25
• 2.2 Removing and installing engine mounting
  31
• 2.3 Removing and installing gearbox mountings
  33
• 2.4 Removing and installing pendulum support
  35
• 2.5 Supporting engine in installation position
  37
• Crankshaft group
  42
• 1 Cylinder block (pulley end)
  42
• 1.1 Assembly overview - poly V-belt drive
  42
• 1.2 Assembly overview - sealing flange, belt pulley end
  44
• 1.3 Removing and installing poly-V belt
  46
• 1.4 Removing and installing tensioner for poly V-belt
  49
• 1.5 Removing and installing vibration damper
  50
• 1.6 Removing and installing engine support
  52
• 1.7 Renewing crankshaft oil seal - belt pulley end
  56
• 1.8 Removing and installing sealing flange on pulley end
  59
• 2 Cylinder block, gearbox end
  63
• 2.1 Assembly overview - cylinder block, gearbox end
  63
• 2.2 Removing and installing flywheel
  65
• 2.3 Removing and installing sealing flange on gearbox side
  66
• 3 Crankshaft
  77
• 3.1 Crankshaft dimensions
  77
• 3.2 Renewing needle bearing in crankshaft
  77
• 3.3 Measuring axial clearance of crankshaft
  80
• 4 Pistons and conrods
  82
• 4.1 Assembly overview - pistons and conrods
  82
• 4.2 Removing and installing pistons
  85
• 4.3 Separating new conrod
  86
• 4.4 Removing and installing oil spray jets
  87
• 4.5 Checking pistons and cylinder bores
  88
• 4.6 Checking radial clearance of conrods
  91
• 4.7 Setting piston to TDC position
  91
• Cylinder head, valve gear
  96
• 1 Cylinder head
  96
• 1.1 Assembly overview - cylinder head
  96
• 1.2 Assembly overview - camshaft housing
  98
• 1.3 Removing and installing cylinder head
  103
• 1.4 Removing and installing camshaft housing
  108
• 1.5 Checking compression
  112
• 2 Toothed belt drive
  115
• 2.1 Assembly overview - toothed belt cover
  115
• 2.2 Assembly overview - toothed belt
  116
• 2.3 Removing and installing toothed belt guard
  120
• 2.4 Checking valve timing
  121
• 2.5 Preassembling and installing valve timing tool
  128
• 2.6 Adjusting valve timing
  143
• 2.7 Removing toothed belt from camshaft
  165
• 2.8 Removing and installing toothed belt
  172
• 3 Valve gear
  180
• 3.1 Assembly overview - valve gear
  180
• 3.2 Removing and installing camshaft oil seal
  182
• 3.3 Removing and installing camshaft adjuster
  196
• 3.4 Removing and installing toothed belt pulley
  215
• 3.5 Removing and installing camshaft control valve 1 N205
  220
• 3.6 Removing and installing exhaust camshaft control valve 1 N318
  221
• 3.7 Removing and installing valve stem seals
  222
• 3.8 Removing and installing cam actuators
  232
• 4 Inlet and exhaust valves
  239
• 4.1 Checking valve guides
  239
• 4.2 Checking valves
  240
• 4.3 Valve dimensions
  240
• Lubrication
  241
• 1 Sump, oil pump
  241
• 1.1 Assembly overview - sump/oil pump
  241
• 1.2 Engine oil:
  245
• 1.3 Removing and installing lower part of sump
  245
• 1.4 Removing and installing upper part of sump
  251
• 1.5 Removing and installing oil pump
  255
• 1.6 Removing and installing oil level and oil temperature sender G266
  257
• 2 Engine oil cooler
  258
• 2.1 Assembly overview - engine oil cooler
  258
• 2.2 Removing and installing engine oil cooler
  258
• 3 Crankcase ventilation
  260
• 3.1 Assembly overview - crankcase breather system
  260
• 3.2 Removing and installing oil separator
  261
• 4 Oil filter, oil pressure switch
  264
• 4.1 Assembly overview - oil filter/oil pressure switch
  264
• 4.2 Removing and installing oil pressure switch F1
  265
• 4.3 Removing and installing oil pressure switch for reduced oil pressure F378
  267
• 4.4 Checking oil pressure
  267
• 4.5 Removing and installing oil pressure regulating valve N428
  270
• Cooling
  271
• 1 Cooling system/coolant
  271
• 1.1 Connection diagram - coolant hoses
  271
• 1.2 Checking cooling system for leaks
  275
• 1.3 Draining and adding coolant
  278
• 2 Coolant pump, regulation of cooling system
  287
• 2.1 Assembly overview - coolant pump, thermostat
  287
• 2.2 Assembly overview - electric coolant pump
  290
• 2.3 Assembly overview - coolant temperature sender
  291
• 2.4 Removing and installing electric coolant pump
  292
• 2.5 Removing and installing coolant pump
  294
• 2.6 Removing and installing thermostat
  300
• 2.7 Removing and installing toothed belt pulley for coolant pump
  303
• 2.8 Removing and installing coolant temperature sender G62
  307
• 2.9 Removing and installing radiator outlet coolant temperature sender G83
  309
• 3 Coolant pipes
  312
• 3.1 Assembly overview - coolant pipes
  312
• 3.2 Removing and installing coolant pipes
  312
• 4 Radiator, radiator fan
  317
• 4.1 Assembly overview - radiator/radiator fan
  317
• 4.2 Assembly overview - radiator cowl and radiator fan
  319
• 4.3 Removing and installing radiator
  320
• 4.4 Removing and installing water radiator for charge air cooling circuit
  325
• 4.5 Removing and installing radiator cowl with radiator fan
  329
• 4.6 Removing and installing radiator fan V7
  330
• Turbocharging/supercharging
  333
• 1 Turbocharger
  333
• 1.1 Assembly overview - turbocharger
  333
• 1.2 Removing and installing turbocharger
  337
• 1.3 Removing and installing charge pressure positioner V465
  343
• 1.4 Removing and installing connection for turbocharger
  345
• 2 Charge air system
  349
• 2.1 Assembly overview - charge air system
  349
• 2.2 Removing and installing charge air cooler
  351
• 2.3 Removing and installing charge pressure sender GX26
  354
• 2.4 Checking charge air system for leaks
  355
• 2.5 Removing and installing air pipe
  357
• Mixture preparation - injection
  360
• 1 Injection system
  360
• 1.1 Overview of fitting locations - injection system
  360
• 2 Injectors
  368
• 2.1 Assembly overview - fuel rail with injectors
  368
• 2.2 Removing and installing fuel rail
  370
• 2.3 Removing and installing injectors
  371
• 2.4 Cleaning injectors
  377
• 3 Air filter
  379
• 3.1 Assembly overview - air filter housing
  379
• 3.2 Removing and installing air filter housing
  379
• 3.3 Removing and installing resonator for intake air
  381
• 4 Intake manifold
  382
• 4.1 Assembly overview - intake manifold
  382
• 4.2 Removing and installing intake manifold
  384
• 4.3 Removing and installing throttle valve module GX3
  388
• 4.4 Cleaning throttle valve module GX3
  390
• 5 Senders and sensors
  392
• 5.1 Removing and installing fuel pressure sender G247
  392
• 5.2 Checking fuel pressure sender G247
  393
• 5.3 Removing and installing intake manifold sender GX9
  397
• 6 Engine control unit
  399
• 6.1 Removing and installing engine control unit J623
  399
• 6.2 Removing and installing engine (motor) control unit J623 with protective housing
  401
• 7 High-pressure pump
  404
• 7.1 Assembly overview - high-pressure pump
  404
• 7.2 Removing and installing high-pressure pump
  409
• 7.3 Removing and installing high-pressure pipe
  411
• 8 Lambda probe
  412
• 8.1 Assembly overview - Lambda probe
  412
• 8.2 Removing and installing Lambda probe
  413
• Exhaust system
  417
• 1 Exhaust pipes and silencers
  417
• 1.1 Assembly overview - silencers
  417
• 1.2 Separating exhaust pipes from silencers
  420
• 1.3 Removing and installing silencer
  421
• 1.4 Aligning exhaust system free of stress
  424
• 1.5 Checking exhaust system for leaks
  425
• 2 Emission control
  426
• 2.1 Assembly overview - emission control
  426
• 2.2 Removing and installing catalytic converter
  428
• Ignition system
  433
• 1 Ignition system
  433
• 1.1 Assembly overview - ignition system
  433
• 1.2 Removing and installing ignition coils with output stage
  435
• 1.3 Removing and installing knock sensor 1 G61
  438
• 1.4 Removing and installing Hall sender
  439
• 1.5 Removing and installing engine speed sender G28
  440