4-cyl. injection engine (1.2 l engine, EA 111, turbocharger)

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Engine number
  1
• 1.2 Engine data
  1
• 2 Safety precautions
  3
• 2.1 Safety measures when working on fuel system
  3
• 2.2 Releasing pressure in high-pressure area
  3
• 3 General repair instructions
  5
• 3.1 Rules for cleanliness
  5
• Removing and installing engine
  6
• 1 Removing and installing engine
  6
• 1.1 Removing engine
  6
• 1.2 Separating gearbox from engine and assembling
  16
• 1.3 Securing engine to assembly stand
  18
• 1.4 Installing engine
  20
• 1.5 Specified torques
  23
• 2 Assembly mountings
  24
• 2.1 Assembly overview - assembly mountings
  24
• 2.2 Adjusting assembly mountings
  25
• 2.3 Checking adjustment of engine assembly mountings
  28
• Crankshaft group
  30
• 1 Dismantling and assembling engine
  30
• 1.1 Assembly overviews
  30
• 1.2 Assembly overview - poly V-belt
  31
• 1.3 Assembly overview - cylinder block
  35
• 1.4 Removing and installing poly-V belt
  39
• 1.5 Removing and installing top valve timing housing
  41
• 1.6 Removing and installing bottom valve timing housing
  44
• 1.7 Removing and installing top ancillary bracket
  48
• 1.8 Removing and installing bottom ancillary bracket
  50
• 2 Removing and installing sealing flange and flywheel
  53
• 2.1 Assembly overview
  53
• 2.2 Removing and installing engine speed sender G28
  55
• 2.3 Renewing crankshaft oil seal - belt pulley end
  55
• 2.4 Removing and installing crankshaft pulley
  58
• 2.5 Renewing crankshaft sealing flange - flywheel end
  62
• 3 Crankshaft
  74
• 3.2 Crankshaft dimensions
  76
• 4 Dismantling and assembling pistons and conrods
  77
• 4.1 Assembly overview
  77
• 4.2 Checking piston
  79
• 4.3 Separating new conrod
  81
• 4.4 Piston and cylinder dimensions
  81
• Cylinder head, valve gear
  83
• 1 Cylinder head
  83
• 1.1 Assembly overview
  83
• 1.2 Checking valve timing
  86
• 1.3 Adjusting valve timing
  90
• 1.4 Removing and installing timing chain and drive chain for oil pump
  99
• 1.5 Removing and installing cylinder head cover and camshaft
  111
• 1.6 Removing and installing cylinder head
  125
• 1.7 Removing and installing cylinder head
  131
• 1.8 Checking compression
  139
• 2 Repairing valve gear
  142
• 2.1 Assembly overview
  142
• 2.2 Checking camshaft axial clearance
  145
• 2.3 Reworking valve seats
  146
• 2.4 Checking valve guides
  147
• 2.5 Renewing valve stem seals
  148
• Lubrication
  151
• 1 Removing and installing parts of lubrication system
  151
• 1.1 Engine oil, oil capacities, engine oil specification
  151
• 1.2 Assembly overview
  151
• 1.3 Removing and installing sump
  154
• 1.4 Removing and installing oil pump
  157
• 1.5 Removing and installing engine oil cooler
  159
• 1.6 Checking oil pressure and oil pressure switch
  159
• Cooling
  162
• 1 Removing and installing parts of cooling system
  162
• 1.1 Assembly overview - parts of cooling system, body side
  163
• 1.2 Assembly overview - parts of cooling system, engine side
  165
• 1.3 Coolant hose connection diagram
  166
• 1.4 Draining and adding coolant
  167
• 1.5 Removing and installing radiator fan V7 and radiator fan 2 V177
  172
• 1.6 Removing and installing radiator
  173
• 1.7 Checking cooling system for leaks
  175
• 1.8 Removing and installing coolant pump pulley
  178
• 1.9 Removing and installing coolant pump
  180
• 1.10 Removing and installing coolant circulation pump V50
  181
• Fuel supply system
  184
• 1 Safety precautions
  184
• 1.1 Safety regulations for working on fuel supply
  184
• 1.2 Releasing pressure in high-pressure area
  185
• 2 Fuel
  186
• 2.1 Assembly overview - fuel tank
  186
• 2.2 Emptying fuel tank
  188
• 2.3 Removing and installing fuel tank
  195
• 3 Repairing fuel supply system
  199
• 3.1 Rules for cleanliness
  199
• 3.2 Removing and installing fuel delivery unit
  199
• 3.3 Removing and installing fuel gauge sender G
  203
• 3.4 Crash fuel shut-off
  204
• 3.5 Checking fuel pump G6
  204
• 4 Electronic power control (EPC)
  222
• 4.1 Function of EPC system
  222
• 4.2 Assembly overview - accelerator module
  222
• 4.3 Removing and installing accelerator pedal module
  223
• 5 Activated charcoal filter system
  227
• 5.1 Function
  227
• 5.2 Assembly overview - activated charcoal filter system
  227
• 5.3 Checking fuel tank breather
  228
• Turbocharging/supercharging
  232
• 1 Turbocharger
  232
• 1.1 General information
  232
• 1.2 Safety precautions
  233
• 1.3 Rules for cleanliness
  234
• 1.4 Assembly overview - turbocharger
  234
• 1.5 Removing and installing turbocharger
  238
• 1.6 Removing and installing charge pressure positioner V465
  243
• 2 Charge air system
  246
• 2.1 Assembly overview - charge air system
  246
• 2.2 Removing and installing charge air cooler in intake manifold
  248
• Mixture preparation - injection
  251
• 1 Injection system
  251
• 1.1 General notes on injection
  251
• 1.2 Safety precautions
  252
• 1.3 Rules for cleanliness
  253
• 1.4 Technical data
  253
• 1.5 Assembly overviews - intake manifold
  254
• 1.6 Assembly overview - part I, intake manifold (vehicles with manual gearbox)
  254
• 1.7 Assembly overview - part II, intake manifold (vehicles with dual clutch gearbox)
  256
• 1.8 Assembly overview - part III, intake manifold
  258
• 1.9 Assembly overview - air filter
  260
• 1.10 Removing and installing air filter
  261
• 1.11 Removing and installing throttle valve module J338
  262
• 1.12 Cleaning throttle valve module J338
  265
• 1.13 Removing and installing intake manifold
  266
• 1.14 Assembly overview - high-pressure pump
  269
• 1.15 Checking fuel pressure sender G247
  270
• 1.16 Removing and installing high-pressure pump
  274
• 1.17 Removing and installing injectors
  276
• 1.18 Renewing Teflon seal and support washer on injector
  280
• 2 Engine control unit
  285
• 2.1 Reading and erasing engine control unit fault memory
  285
• 2.2 Removing and installing engine control unit
  286
• Exhaust system
  292
• 1 Removing and installing parts of exhaust system
  292
• 1.1 Assembly overview - catalytic converter and attachments
  293
• 1.2 Assembly overview - silencers with mountings
  295
• 1.3 Separating and joining front and rear silencers
  297
• 1.4 Aligning exhaust system free of stress
  299
• Ignition system
  301
• 1 Repairing ignition system
  301
• 1.1 Assembly overview - ignition system
  301
• 1.2 Safety precautions
  303
• 1.3 Test data, spark plugs
  303