4-cylinder direct injection engine (1.4-l engine, 4 V, EA 211, turbocharger, hybrid)

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety measures for working on vehicles with high-voltage system
  1
• 1.2 Safety regulations for working on fuel supply
  2
• 1.4 Safety precautions when working on the cooling system
  3
• 1.5 Safety precautions when working on ignition system
  3
• 2 Identification
  4
• 2.1 Engine number/engine data
  4
• 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
  6
• 3.5 Fitting radiator and condensers
  6
• 3.6 Checking vacuum system
  6
• Removing and installing engine
  7
• 1 Removing and installing engine
  7
• 1.1 Removing engine
  7
• 1.2 Separating engine and gearbox
  19
• 1.3 Separating electric drive motor V141 and engine
  23
• 1.4 Securing engine on engine and gearbox support
  31
• 1.5 Connecting electric drive motor V141 and engine
  32
• 1.6 Installing engine
  50
• 2 Assembly mountings
  56
• 2.1 Assembly overview - assembly mountings
  56
• 2.2 Removing and installing motor mounting
  58
• 2.3 Removing and installing gearbox mounting
  62
• 2.4 Removing and installing pendulum support
  68
• 2.5 Adjusting assembly mountings
  69
• 2.6 Checking adjustment of assembly mountings (engine and gearbox mountings)
  79
• 3 Motor cover
  81
• 3.1 Removing and installing engine cover
  81
• Crankshaft group
  82
• 1 Cylinder block (pulley end)
  82
• 1.1 Assembly overview - sealing flange, belt pulley end
  82
• 1.2 Removing and installing vibration damper
  83
• 1.3 Removing and installing engine bracket
  84
• 1.4 Renewing crankshaft oil seal - belt pulley end
  85
• 1.5 Removing and installing sealing flange on pulley end
  87
• 2 Cylinder block, gearbox end
  90
• 2.1 Assembly overview - cylinder block, gearbox end
  90
• 2.2 Removing and installing sealing flange on gearbox side
  92
• 3 Crankshaft
  101
• 3.1 Crankshaft dimensions
  101
• 3.2 Measuring axial clearance of crankshaft
  101
• 4 Pistons and conrods
  103
• 4.1 Assembly overview - pistons and conrods
  103
• 4.2 Removing and installing pistons
  105
• 4.3 Checking pistons and cylinder bores
  106
• 4.4 Checking radial clearance of conrods
  107
• 4.5 Removing and installing oil spray jets
  108
• Cylinder head, valve gear
  110
• 1 Cylinder head
  110
• 1.1 Assembly overview - cylinder head
  110
• 1.2 Assembly overview - camshaft housing
  111
• 1.3 Removing and installing cylinder head
  113
• 1.4 Removing and installing camshaft housing
  117
• 1.5 Checking compression
  121
• 2 Toothed belt drive
  124
• 2.1 Assembly overview - toothed belt cover
  124
• 2.2 Assembly overview - toothed belt
  125
• 2.3 Removing and installing toothed belt guard
  126
• 2.4 Removing and installing toothed belt
  127
• 2.5 Checking valve timing
  133
• 2.6 Adjusting valve timing
  139
• 2.7 Removing toothed belt from camshaft
  146
• 3 Valve gear
  150
• 3.1 Assembly overview - valve gear
  150
• 3.2 Measuring axial play of camshaft
  151
• 3.3 Removing and installing camshaft oil seal
  152
• 3.4 Removing and installing camshaft adjuster
  158
• 3.5 Removing and installing camshaft control valve 1 N205
  166
• 3.6 Removing and installing exhaust camshaft control valve 1 N318
  167
• 3.7 Removing and installing valve stem seals
  167
• 4 Inlet and exhaust valves
  174
• 4.1 Checking valve guides
  174
• 4.2 Checking valves
  174
• 4.3 Valve dimensions
  175
• Lubrication
  176
• 1 Sump, oil pump
  176
• 1.1 Assembly overview - sump/oil pump
  176
• 1.2 Engine oil:
  179
• 1.3 Removing and installing lower part of sump
  180
• 1.4 Removing and installing upper part of sump
  184
• 1.5 Removing and installing oil pump
  189
• 1.6 Removing and installing oil level and oil temperature sender G266
  190
• 2 Engine oil cooler
  192
• 2.1 Assembly overview - engine oil cooler
  192
• 2.2 Removing and installing engine oil cooler
  192
• 3 Crankcase ventilation
  194
• 3.1 Assembly overview - crankcase breather system
  194
• 3.2 Removing and installing oil separator
  195
• 4 Oil filter, oil pressure switch
  197
• 4.1 Assembly overview - oil filter/oil pressure switch
  197
• 4.2 Removing and installing oil pressure switch F22
  198
• 4.3 Removing and installing oil pressure switch for reduced oil pressure F378
  199
• 4.4 Checking oil pressure
  200
• 4.5 Removing and installing oil pressure regulating valve N428
  202
• Cooling
  203
• 1 Cooling system/coolant
  203
• 1.1 Connection diagram - coolant hoses
  203
• 1.2 Checking cooling system for leaks
  204
• 1.3 Draining and adding coolant
  206
• 2 Coolant pump, regulation of cooling system
  213
• 2.1 Assembly overview - coolant pump, thermostat
  213
• 2.2 Assembly overview - electric coolant pump
  218
• 2.3 Assembly overview - coolant temperature sender
  219
• 2.4 Removing and installing electric coolant pump
  219
• 2.5 Removing and installing coolant pump
  223
• 2.6 Removing and installing thermostat
  229
• 2.7 Removing and installing toothed belt pulley for coolant pump
  231
• 2.8 Removing and installing coolant temperature sender G62
  235
• 2.9 Removing and installing radiator outlet coolant temperature sender G83
  236
• 3 Coolant pipes
  238
• 3.1 Assembly overview - coolant pipes
  238
• 3.2 Removing and installing coolant pipes
  238
• 4 Radiator, radiator fan
  241
• 4.1 Assembly overview - radiator/radiator fan
  241
• 4.2 Removing and installing radiator
  242
• 4.3 Removing and installing radiator cowl
  244
• 4.4 Removing and installing radiator fan
  245
• Turbocharging/supercharging
  247
• 1 Exhaust turbocharger
  247
• 1.1 Assembly overview - turbocharger
  247
• 1.2 Removing and installing turbocharger
  250
• 1.3 Removing and installing charge pressure positioner V465
  257
• 1.4 Removing and installing connection for turbocharger
  260
• 2 Charge air system
  264
• 2.1 Assembly overview - charge air system
  264
• 2.2 Removing and installing charge air cooler
  266
• 2.3 Removing and installing charge pressure sender GX26
  269
• 2.4 Checking charge air system for leaks
  269
• 2.5 Removing and installing air pipe
  271
• Mixture preparation - injection
  273
• 1 Injectors
  273
• 1.1 Assembly overview - fuel rail with injectors
  273
• 1.2 Removing and installing fuel rail
  274
• 1.3 Removing and installing injectors
  274
• 1.4 Cleaning injectors
  278
• 2 Air filter
  280
• 2.1 Assembly overview - air filter housing
  280
• 2.2 Removing and installing air filter housing
  281
• 2.3 Removing and installing resonator for intake air
  282
• 3 Intake manifold
  283
• 3.1 Assembly overview - intake manifold
  283
• 3.2 Removing and installing intake manifold
  284
• 3.3 Removing and installing throttle valve module GX3
  287
• 3.4 Cleaning throttle valve module GX3
  288
• 4 Senders and sensors
  290
• 4.1 Removing and installing fuel pressure sender G247
  290
• 4.2 Checking fuel pressure sender G247
  291
• 4.3 Removing and installing intake manifold sender GX9
  294
• 5 Engine (motor) control unit
  296
• 5.1 Removing and installing engine (motor) control unit J623
  296
• 6 High-pressure pump
  300
• 6.1 Assembly overview - high-pressure pump
  300
• 6.2 Removing and installing high-pressure pump
  301
• 6.3 Removing and installing high-pressure pipe
  303
• 7 Lambda probe
  306
• 7.1 Assembly overview - Lambda probe
  306
• 7.2 Removing and installing Lambda probe
  307
• Exhaust system
  312
• 1 Exhaust pipes and silencers
  312
• 1.1 Assembly overview - silencers
  312
• 1.2 Removing and installing rear silencer
  313
• 1.3 Aligning exhaust system free of stress
  314
• 1.4 Check exhaust system for leaks
  315
• 1.5 Installation position of clamp
  315
• 2 Exhaust gas cleaning
  318
• 2.1 Assembly overview - emission control
  318
• 2.2 Removing and installing catalytic converter
  319
• 3 Secondary air system
  324
• 3.1 Assembly overview - secondary air system
  324
• 3.2 Removing and installing secondary air pump motor V101
  325
• 3.3 Removing and installing secondary air inlet valve N112
  325
• Ignition system
  326
• 1 Ignition system
  326
• 1.1 Assembly overview - ignition system
  326
• 1.2 Test data, spark plugs
  327
• 1.3 Removing and installing ignition coils with output stage
  327
• 1.4 Removing and installing knock sensor 1 G61
  330
• 1.5 Removing and installing Hall sender
  330
• 1.6 Removing and installing engine speed sender G28
  332