4-cylinder direct injection engine (1.2 l engine, 2V, EA 111, turbocharger)

Chapter overview

• Technical data
  1
• 1 Engine number/engine data
  1
• 2 Safety precautions
  5
• 2.1 Safety regulations for working on fuel supply
  5
• 2.2 Releasing high pressure in fuel system
  6
• 2.4 Safety precautions when working on the cooling system
  7
• 2.5 Safety precautions when working on ignition system
  8
• 3 General repair instructions
  9
• 3.1 Rules for cleanliness
  9
• 3.2 Foreign objects in engine
  9
• 3.3 Contact corrosion
  9
• 3.4 Routing and attachment of lines
  9
• 3.5 Fitting radiator and condensers
  10
• Removing and installing engine
  11
• 1 Removing and installing engine
  11
• 1.1 Removing engine
  11
• 1.2 Installing engine
  34
• 2 Assembly mountings
  42
• 2.1 Assembly overview - assembly mountings
  42
• Crankshaft group
  45
• 1 Cylinder block (pulley end)
  45
• 1.1 Assembly overview - poly V-belt drive
  45
• 1.2 Removing and installing poly-V belt
  47
• 1.3 Removing and installing crankshaft pulley
  48
• 1.4 Renewing crankshaft oil seal - belt pulley end
  52
• 2 Cylinder block, gearbox end
  55
• 2.1 Assembly overview - cylinder block, gearbox end
  55
• 2.2 Removing and installing flywheel
  57
• 2.3 Removing and installing crankshaft sealing flange on gearbox side
  58
• 2.4 Removing and installing bracket for ancillaries
  65
• 3 Crankshaft
  70
• 3.1 Renewing needle bearing in crankshaft
  70
• 3.2 Measuring axial clearance of crankshaft
  72
• 3.3 Crankshaft dimensions
  73
• 4 Pistons and conrods
  74
• 4.1 Assembly overview - pistons and conrods
  74
• 4.2 Checking pistons and cylinder bores
  75
• 4.3 Removing and installing oil spray jets
  76
• 4.4 Separating new conrod
  77
• Cylinder head, valve gear
  79
• 1 Cylinder head
  79
• 1.1 Assembly overview - cylinder head
  79
• 1.2 Removing and installing cylinder head cover and camshaft
  82
• 1.3 Removing and installing cylinder head
  96
• 1.4 Checking compression
  102
• 2 Valve gear
  104
• 2.1 Assembly overview - valve gear
  104
• 2.2 Measuring axial play of camshaft
  106
• 2.3 Removing and installing valve stem seals
  107
• 3 Inlet and exhaust valves
  109
• 3.1 Checking valve guides
  109
• 3.2 Checking valves
  109
• 3.3 Valve dimensions
  111
• 3.4 Reworking valve seats
  111
• 4 Cover for timing chain
  112
• 4.1 Removing and installing top valve timing housing
  112
• 4.2 Removing and installing bottom valve timing housing
  115
• 5 Chain drive
  120
• 5.1 Assembly overview - timing chain
  120
• 5.2 Checking valve timing
  125
• 5.3 Adjusting valve timing
  127
• 5.4 Removing and installing timing chain
  136
• 5.5 Removing and installing timing chain and chain drive for oil pump
  145
• Lubrication
  149
• 1 Sump, oil pump
  149
• 1.1 Assembly overview - sump/oil pump
  149
• 1.2 Engine oil:
  153
• 1.3 Removing and installing sump
  153
• 1.4 Removing and installing oil pump
  158
• 2 Oil filter, oil pressure switch
  160
• 2.1 Assembly overview - oil filter
  160
• 2.2 Checking oil pressure and oil pressure switch
  161
• 2.3 Removing and installing non-return valve
  162
• 3 Engine oil cooler
  164
• 3.1 Removing and installing engine oil cooler
  164
• 4 Crankcase ventilation
  165
• 4.1 Assembly overview - crankcase breather system
  165
• 4.2 Removing and installing oil separator
  166
• Cooling
  169
• 1 Cooling system/coolant
  169
• 1.1 Coolant hose connection diagram
  169
• 1.2 Draining and adding coolant
  171
• 1.3 Checking cooling system for leaks
  175
• 2 Coolant pump, regulation of cooling system
  178
• 2.1 Assembly overview - thermostat
  178
• 2.2 Removing and installing coolant pump
  179
• 2.3 Removing and installing coolant circulation pump V50
  180
• 3 Radiator, radiator fan
  183
• 3.1 Assembly overview - radiator/radiator fan
  183
• 3.2 Removing and installing radiator
  187
• 3.3 Removing and installing radiator fan V7
  194
• Turbocharging/supercharging
  197
• 1 Exhaust turbocharger
  197
• 1.1 Assembly overview - turbocharger
  197
• 1.2 Removing and installing turbocharger
  199
• 1.3 Removing and installing charge pressure positioner V465
  205
• 2 Charge air system
  208
• 2.1 Assembly overview - charge air system
  208
• 2.2 Removing and installing charge air cooler (intake manifold)
  212
• Mixture preparation - injection
  214
• 1 Injection system
  214
• 2 Air filter
  215
• 2.1 Assembly overview - air filter
  215
• 2.2 Removing and installing air filter housing
  217
• 3 Intake manifold
  219
• 3.1 Assembly overview - intake manifold
  219
• 3.2 Removing and installing intake manifold
  223
• 3.3 Removing and installing throttle valve module J338
  224
• 3.4 Cleaning throttle valve module J338
  226
• 4 Injectors
  228
• 4.1 Removing and installing injectors
  228
• 4.2 Renewing seals on injectors
  230
• 4.3 Cleaning injectors
  234
• 5 High-pressure pump
  236
• 5.1 Assembly overview - high-pressure pump
  236
• 5.2 Removing and installing high-pressure pump
  237
• 6 Senders and sensors
  241
• 6.1 Checking fuel pressure sender G247
  241
• 7 Engine control unit J623
  245
• 7.1 Removing and installing engine (motor) control unit J623
  245
• Exhaust system
  255
• 1 Exhaust pipes and silencers
  255
• 1.1 Assembly overview - silencers
  255
• 1.2 Separating exhaust pipes from silencers
  257
• 1.3 Installation position of clamp
  259
• 2 Exhaust gas cleaning
  261
• 2.1 Assembly overview - emission control
  261
• 2.2 Removing and installing catalytic converter (Polo)
  265
• Ignition system
  267
• 1 Ignition system
  267
• 1.1 Assembly overview - ignition system
  267
• 1.2 Removing and installing engine speed sender G28
  269
• 1.3 Test data, spark plugs
  269