4-cylinder direct injection engine (1.5 l engine, 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 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
  6
• 3.1 Rules for cleanliness
  6
• 3.2 General information
  6
• 3.3 General repair instructions
  6
• 3.4 Foreign objects in engine
  7
• 3.5 Contact corrosion
  7
• 3.6 Routing and attachment of lines
  7
• 3.7 Fitting radiator and condensers
  7
• 3.8 Checking vacuum system
  7
• Removing and installing engine
  9
• 1 Removing and installing engine
  9
• 1.1 Removing engine
  9
• 1.2 Separating engine and gearbox
  18
• 1.3 Securing engine on engine and gearbox support
  21
• 1.4 Installing engine
  23
• 2 Assembly mountings
  28
• 2.1 Assembly overview – assembly mountings
  28
• 2.2 Removing and installing engine mounting
  30
• 2.3 Removing and installing gearbox mounting
  31
• 2.4 Removing and installing pendulum support
  33
• 2.5 Supporting engine in installation position
  34
• 2.6 Adjusting assembly mountings
  39
• 2.7 Checking adjustment of assembly mountings
  42
• 3 Engine cover panel
  43
• 3.1 Removing and installing engine cover
  43
• Crankshaft group
  44
• 1 Cylinder block (pulley end)
  44
• 1.1 Assembly overview - poly V-belt drive
  44
• 1.2 Removing and installing poly-V belt
  48
• 1.3 Removing and installing tensioner for poly V-belt
  52
• 1.4 Removing and installing vibration damper
  53
• 1.5 Removing and installing engine support
  56
• 1.6 Renewing crankshaft oil seal - belt pulley end
  59
• 2 Cylinder block, gearbox end
  63
• 2.1 Assembly overview - cylinder block, gearbox end
  63
• 2.2 Removing and installing flywheel
  66
• 2.3 Removing and installing sealing flange on gearbox side
  67
• 3 Crankshaft
  80
• 3.1 Renewing needle bearing in crankshaft
  80
• 3.2 Crankshaft dimensions
  82
• 3.3 Measuring axial clearance of crankshaft
  82
• 4 Pistons and conrods
  84
• 4.1 Assembly overview - pistons and conrods
  84
• 4.2 Removing and installing pistons
  86
• 4.3 Checking pistons and cylinder bores
  88
• 4.4 Separating new conrod
  90
• 4.5 Checking radial clearance of conrods
  90
• 4.6 Removing and installing oil spray jets
  91
• 4.7 Setting piston to TDC position
  92
• Cylinder head, valve gear
  95
• 1 Cylinder head
  95
• 1.1 Assembly overview - cylinder head
  95
• 1.2 Assembly overview - camshaft housing
  97
• 1.3 Removing and installing cylinder head
  100
• 1.4 Removing and installing camshaft housing
  104
• 1.5 Checking compression
  109
• 2 Toothed belt drive
  112
• 2.1 Assembly overview - toothed belt cover
  112
• 2.2 Assembly overview - toothed belt
  113
• 2.3 Assembly overview - valve timing tool
  116
• 2.4 Removing and installing toothed belt guard
  116
• 2.5 Removing and installing toothed belt
  117
• 2.6 Preassembling and installing valve timing tool
  124
• 2.7 Checking valve timing
  134
• 2.8 Adjusting valve timing
  137
• 2.9 Removing toothed belt from camshaft
  147
• 3 Valve gear
  152
• 3.1 Assembly overview - valve gear
  152
• 3.2 Removing and installing camshaft oil seal
  155
• 3.3 Removing and installing camshaft adjuster
  167
• 3.4 Removing and installing cam actuators
  180
• 3.5 Removing and installing inlet camshaft control valve 1 N727
  182
• 3.6 Removing and installing exhaust camshaft control valve 1 N318
  183
• 3.7 Removing and installing valve stem oil seals
  184
• 3.8 Removing and installing holder for oil seal
  199
• 4 Inlet and exhaust valves
  203
• 4.1 Checking valve guides
  203
• 4.2 Checking valves
  204
• 4.3 Valve dimensions
  204
• Lubrication
  205
• 1 Sump, oil pump
  205
• 1.1 Assembly overview - sump/oil pump
  205
• 1.2 Engine oil:
  210
• 1.3 Removing and installing oil sump
  210
• 1.4 Removing and installing oil pump
  215
• 1.5 Removing and installing oil level and oil temperature sender G266
  218
• 2 Engine oil cooler
  219
• 2.1 Assembly overview - engine oil cooler
  219
• 2.2 Removing and installing engine oil cooler
  219
• 3 Crankcase ventilation
  221
• 3.1 Assembly overview - crankcase breather system
  221
• 3.2 Removing and installing oil separator
  222
• 4 Oil filter, oil pressure switch
  227
• 4.1 Assembly overview - oil pressure switches/oil pressure control
  227
• 4.2 Removing and installing oil pressure sender G10
  227
• 4.3 Checking oil pressure and oil pressure switch
  229
• 4.4 Removing and installing oil filter housing
  229
• 4.5 Removing and installing oil pressure regulating valve N428
  230
• Cooling
  232
• 1 Cooling system/coolant
  232
• 1.1 Connection diagram - coolant hoses
  232
• 1.2 Checking cooling system for leaks
  234
• 1.3 Draining and adding coolant
  237
• 1.4 Flushing cooling system
  246
• 2 Coolant pump, regulation of cooling system
  261
• 2.1 Assembly overview - coolant pump, thermostat
  261
• 2.2 Assembly overview - electric coolant pump
  263
• 2.3 Assembly overview - coolant temperature sender
  263
• 2.4 Removing and installing electric coolant pump
  264
• 2.5 Removing and installing coolant pump
  267
• 2.6 Removing and installing toothed belt pulley for coolant pump
  272
• 2.7 Removing and installing coolant temperature sender G62
  276
• 2.8 Removing and installing radiator outlet coolant temperature sender G83
  278
• 2.9 Removing and installing engine outlet coolant temperature sender G82
  279
• 2.10 Removing and installing engine temperature regulation module GX33
  281
• 2.11 Checking coolant pump
  286
• 3 Coolant pipes
  292
• 3.1 Assembly overview - coolant pipes
  292
• 3.2 Removing and installing coolant pipes
  294
• 4 Radiator, radiator fan
  303
• 4.1 Assembly overview - radiator, radiator fan
  303
• 4.2 Assembly overview – radiator cowl and radiator fan
  305
• 4.3 Removing and installing radiator
  306
• 4.4 Removing and installing water radiator for charge air cooling circuit
  309
• 4.5 Removing and installing radiator cowl
  314
• 4.6 Removing and installing radiator fan V7
  315
• Turbocharging/supercharging
  317
• 1 Turbocharger
  317
• 1.1 Assembly overview - turbocharger
  317
• 1.2 Removing and installing turbocharger
  321
• 1.3 Removing and installing connection for turbocharger
  326
• 1.4 Removing and installing charge pressure control module GX34
  328
• 2 Charge air system
  333
• 2.1 Assembly overview - charge air system
  333
• 2.2 Removing and installing charge air cooler
  336
• 2.3 Removing and installing charge pressure sender GX26
  338
• 2.4 Checking charge air system for leaks
  339
• 2.5 Removing and installing air intake pipe
  343
• 2.6 Checking charge air cooler for leaks
  349
• Mixture preparation - injection
  355
• 1 Injection system
  355
• 1.1 Overview of fitting locations - injection system
  355
• 2 Air filter
  363
• 2.1 Assembly overview - air filter housing
  363
• 2.2 Removing and installing air filter housing
  365
• 2.3 Removing and installing air guide on lock carrier
  367
• 3 Intake manifold
  369
• 3.1 Assembly overview – intake manifold
  369
• 3.2 Removing and installing intake manifold
  372
• 3.3 Removing and installing throttle valve module GX3
  376
• 3.4 Cleaning throttle valve module GX3
  378
• 4 Injectors
  380
• 4.1 Assembly overview - fuel rail with injectors
  380
• 4.2 Removing and installing fuel rail
  382
• 4.3 Removing and installing injectors
  383
• 4.4 Cleaning injectors
  390
• 5 Senders and sensors
  393
• 5.1 Removing and installing intake manifold sender GX9
  393
• 5.2 Removing and installing fuel pressure sender G247
  394
• 5.3 Checking fuel pressure sender G247
  396
• 5.4 Removing and installing exhaust gas pressure sensor 1 G450
  400
• 5.5 Removing and installing air mass measurement module GX35
  401
• 6 High-pressure pump
  403
• 6.1 Assembly overview - high-pressure pump
  403
• 6.2 Removing and installing high-pressure pump
  404
• 6.3 Removing and installing high-pressure pipe
  406
• 7 Lambda probe
  409
• 7.1 Assembly overview - Lambda probe
  409
• 7.2 Removing and installing Lambda probe
  410
• 8 Engine control unit
  412
• 8.1 Removing and installing engine control unit J623
  412
• Exhaust system
  420
• 1 Exhaust pipes and silencers
  420
• 1.1 Assembly overview – silencers
  420
• 1.2 Removing and installing silencer
  422
• 1.3 Separating exhaust pipes from silencers
  424
• 1.4 Aligning exhaust system free of stress
  426
• 1.5 Checking exhaust system for leaks
  426
• 1.6 Installation position of clamp
  427
• 1.7 Assembly overview - front exhaust pipe
  428
• 1.8 Removing and installing bracket for front exhaust pipe
  428
• 2 Emission control
  430
• 2.1 Assembly overview – emission control
  430
• 2.2 Removing and installing catalytic converter
  433
• 2.3 Removing and installing particulate filter
  438
• 2.4 Removing and installing exhaust flap control unit J883
  439
• Ignition system
  440
• 1 Ignition system
  440
• 1.1 Assembly overview - ignition system
  440
• 1.2 Removing and installing ignition coils with output stage
  442
• 1.3 Removing and installing knock sensor 1 G61
  446
• 1.4 Removing and installing engine speed sender G28
  447
• 1.5 Removing and installing inlet camshaft position sender G1002
  449
• 1.6 Removing and installing exhaust camshaft position sender G1003
  450