4-cylinder direct injection engine (1.4 l engine, 4V, EA211, 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 engine
  7
• 1.1 Removing engine
  7
• 1.2 Separating engine and gearbox
  21
• 1.3 Securing engine on engine and gearbox support
  23
• 1.4 Installing engine
  24
• 2 Assembly mountings
  28
• 2.1 Assembly overview – assembly mountings
  28
• 2.2 Removing and installing engine mounting
  31
• 2.3 Removing and installing gearbox mounting
  31
• 2.4 Removing and installing pendulum support
  34
• 2.5 Supporting engine in installation position
  35
• 2.6 Adjusting assembly mountings
  45
• 2.7 Checking adjustment of assembly mountings
  48
• Crankshaft group
  49
• 1 Cylinder block (pulley end)
  49
• 1.1 Assembly overview - poly V-belt drive
  49
• 1.2 Assembly overview - sealing flange, belt pulley end
  53
• 1.3 Removing and installing poly-V belt
  55
• 1.4 Removing and installing tensioner for poly V-belt
  58
• 1.5 Removing and installing vibration damper
  59
• 1.6 Removing and installing engine support
  61
• 1.7 Renewing crankshaft oil seal - belt pulley end
  64
• 1.8 Removing and installing sealing flange on pulley end
  67
• 2 Cylinder block, gearbox end
  71
• 2.1 Assembly overview - cylinder block, gearbox end, flywheel
  71
• 2.2 Assembly overview - cylinder block, gearbox end, drive plate
  72
• 2.3 Removing and installing flywheel
  74
• 2.4 Removing and installing drive plate
  75
• 2.5 Removing and installing sealing flange on gearbox side
  78
• 3 Crankshaft
  89
• 3.1 Crankshaft dimensions
  89
• 3.2 Renewing needle bearing in crankshaft
  89
• 3.3 Measuring axial clearance of crankshaft
  92
• 4 Pistons and conrods
  94
• 4.1 Assembly overview - pistons and conrods
  94
• 4.2 Removing and installing pistons
  97
• 4.3 Checking pistons and cylinder bores
  98
• 4.4 Separating new conrod
  100
• 4.5 Checking radial clearance of conrods
  101
• 4.6 Removing and installing oil spray jets
  101
• Cylinder head, valve gear
  104
• 1 Cylinder head
  104
• 1.1 Assembly overview - cylinder head
  104
• 1.2 Assembly overview - camshaft housing
  106
• 1.3 Removing and installing cylinder head
  110
• 1.4 Removing and installing camshaft housing
  115
• 1.5 Checking compression
  120
• 2 Toothed belt drive
  123
• 2.1 Assembly overview - toothed belt cover
  123
• 2.2 Assembly overview - toothed belt
  124
• 2.3 Removing and installing toothed belt guard
  128
• 2.4 Removing and installing toothed belt
  129
• 2.5 Checking valve timing
  142
• 2.6 Adjusting valve timing
  149
• 2.7 Removing toothed belt from camshaft
  167
• 3 Valve gear
  172
• 3.1 Assembly overview - valve gear
  172
• 3.2 Measuring axial play of camshaft
  174
• 3.3 Removing and installing camshaft oil seal
  175
• 3.4 Removing and installing camshaft adjuster
  182
• 3.5 Removing and installing camshaft control valve 1 N205
  200
• 3.6 Removing and installing exhaust camshaft control valve 1 N318
  201
• 3.7 Removing and installing valve stem seals
  201
• 3.8 Removing and installing toothed belt pulley
  211
• 4 Inlet and exhaust valves
  214
• 4.1 Checking valve guides
  214
• 4.2 Checking valves
  215
• 4.3 Valve dimensions
  215
• Lubrication
  216
• 1 Sump, oil pump
  216
• 1.1 Assembly overview - sump/oil pump
  216
• 1.2 Engine oil:
  220
• 1.3 Removing and installing lower part of sump
  220
• 1.4 Removing and installing upper part of sump
  226
• 1.5 Removing and installing oil pump
  233
• 1.6 Removing and installing oil level and oil temperature sender G266
  235
• 2 Engine oil cooler
  236
• 2.1 Assembly overview - engine oil cooler
  236
• 2.2 Removing and installing engine oil cooler
  236
• 3 Crankcase ventilation
  238
• 3.1 Assembly overview - crankcase breather system
  238
• 3.2 Removing and installing oil separator
  239
• 4 Oil filter, oil pressure switch
  243
• 4.1 Assembly overview - oil filter/oil pressure switch
  243
• 4.2 Removing and installing oil pressure switch F1
  244
• 4.3 Removing and installing oil pressure switch for reduced oil pressure F378
  245
• 4.4 Checking oil pressure
  246
• 4.5 Removing and installing oil pressure regulating valve N428
  248
• Cooling
  249
• 1 Cooling system/coolant
  249
• 1.1 Connection diagram - coolant hoses
  249
• 1.2 Assembly overview - engine preheater
  250
• 1.3 Checking cooling system for leaks
  251
• 1.4 Draining and adding coolant
  254
• 1.5 Removing and installing engine preheating element Z97
  263
• 2 Coolant pump, regulation of cooling system
  266
• 2.1 Assembly overview - coolant pump, thermostat
  266
• 2.2 Assembly overview - electric coolant pump
  269
• 2.3 Assembly overview - coolant temperature sender
  269
• 2.4 Removing and installing electric coolant pump
  270
• 2.5 Removing and installing coolant pump
  272
• 2.6 Removing and installing thermostat
  277
• 2.7 Removing and installing toothed belt pulley for coolant pump
  280
• 2.8 Removing and installing coolant temperature sender G62
  282
• 2.9 Removing and installing radiator outlet coolant temperature sender G83
  283
• 3 Coolant pipes
  285
• 3.1 Assembly overview - coolant pipes
  285
• 3.2 Removing and installing coolant pipes
  286
• 4 Radiator, radiator fan
  291
• 4.1 Assembly overview - radiator/radiator fan
  291
• 4.2 Assembly overview – radiator cowl and radiator fan
  293
• 4.3 Assembly overview - radiator blind
  295
• 4.4 Removing and installing radiator
  298
• 4.5 Removing and installing water radiator for charge air cooling circuit
  302
• 4.6 Removing and installing radiator cowl
  308
• 4.7 Removing and installing radiator fan
  310
• 4.8 Removing and installing radiator blind
  312
• 4.9 Removing and installing radiator blind control motor V544
  314
• Turbocharging/supercharging
  320
• 1 Turbocharger
  320
• 1.1 Assembly overview - turbocharger
  320
• 1.2 Removing and installing turbocharger
  324
• 1.3 Removing and installing charge pressure positioner V465
  330
• 2 Charge air system
  334
• 2.1 Assembly overview - charge air system
  334
• 2.2 Removing and installing charge air cooler
  337
• 2.3 Removing and installing charge pressure sender GX26
  340
• 2.4 Checking charge air system for leaks
  340
• 2.5 Removing and installing air pipe
  342
• Mixture preparation - injection
  344
• 1 Injection system
  344
• 1.1 Overview of fitting locations - injection system
  344
• 2 Injectors
  349
• 2.1 Assembly overview - fuel rail with injectors
  349
• 2.2 Removing and installing fuel rail
  350
• 2.3 Removing and installing injectors
  350
• 2.4 Cleaning injectors
  358
• 3 Air filter
  360
• 3.1 Assembly overview - air filter housing
  360
• 3.2 Removing and installing air filter housing
  363
• 3.3 Removing and installing resonator for intake air
  368
• 4 Intake manifold
  369
• 4.1 Assembly overview – intake manifold
  369
• 4.2 Removing and installing intake manifold
  371
• 4.3 Removing and installing throttle valve module GX3
  379
• 4.4 Cleaning throttle valve module GX3
  380
• 4.5 Removing and installing activated charcoal filter solenoid valve 1 N80
  381
• 5 Senders and sensors
  383
• 5.1 Removing and installing fuel pressure sender G247
  383
• 5.2 Checking fuel pressure sender G247
  384
• 5.3 Removing and installing intake manifold sender GX9
  386
• 6 Engine control unit
  388
• 6.1 Removing and installing engine control unit J623
  388
• 7 High-pressure pump
  395
• 7.1 Assembly overview - high-pressure pump
  395
• 7.2 Removing and installing high-pressure pump
  399
• 7.3 Removing and installing high-pressure pipe
  401
• 8 Lambda probe
  404
• 8.1 Assembly overview - Lambda probe
  404
• 8.2 Removing and installing Lambda probe
  405
• Exhaust system
  409
• 1 Exhaust pipes and silencers
  409
• 1.1 Assembly overview – silencers
  409
• 1.2 Separating exhaust pipes from silencers
  412
• 1.3 Removing and installing silencer
  414
• 1.4 Aligning exhaust system free of stress
  417
• 1.5 Checking exhaust system for leaks
  418
• 2 Emission control
  419
• 2.1 Assembly overview – emission control
  419
• 2.2 Removing and installing catalytic converter
  422
• 3 Secondary air system
  427
• 3.1 Assembly overview - secondary air system
  427
• 3.2 Removing and installing secondary air pump motor V101
  428
• 3.3 Removing and installing secondary air inlet valve N112
  429
• Ignition system
  432
• 1 Ignition system
  432
• 1.1 Assembly overview - ignition system
  432
• 1.2 Test data, spark plugs
  434
• 1.3 Removing and installing ignition coils with output stage
  434
• 1.4 Removing and installing knock sensor 1 G61
  437
• 1.5 Removing and installing Hall sender
  437
• 1.6 Removing and installing engine speed sender G28
  438