4-cylinder injection engine (1.2 l, 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
  4
• 3.1 Rules for cleanliness
  4
• 3.2 Foreign objects in engine
  4
• 3.3 Contact corrosion
  4
• 3.4 Routing and attachment of lines
  4
• 3.5 Fitting radiator and condensers
  5
• Removing and installing engine
  6
• 1 Removing and installing engine
  6
• 1.1 Removing engine
  6
• 1.2 Separating engine and gearbox
  18
• 1.3 Securing engine on engine and gearbox support
  20
• 1.4 Installing engine
  22
• 2 Assembly mountings
  25
• 2.1 Assembly overview - assembly mountings
  25
• 2.2 Removing and installing engine mounting
  28
• 2.3 Removing and installing gearbox mounting
  30
• 2.4 Removing and installing pendulum support
  32
• 2.5 Supporting engine in installation position
  32
• 2.6 Adjusting assembly mountings
  41
• 2.7 Checking adjustment of assembly mountings
  43
• 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
  49
• 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
  55
• 1.6 Renewing crankshaft oil seal - belt pulley end
  57
• 2 Cylinder block, gearbox end
  61
• 2.1 Assembly overview - cylinder block, gearbox end
  61
• 2.2 Removing and installing flywheel
  62
• 2.3 Removing and installing sealing flange on gearbox side
  63
• 3 Crankshaft
  74
• 3.1 Crankshaft dimensions
  74
• 3.2 Renewing needle bearing in crankshaft
  74
• 3.3 Measuring axial clearance of crankshaft
  77
• 4 Pistons and conrods
  79
• 4.1 Assembly overview - pistons and conrods
  79
• 4.2 Removing and installing pistons
  82
• 4.3 Checking pistons and cylinder bores
  83
• 4.4 Separating new conrod
  85
• 4.5 Checking radial clearance of conrods
  86
• 4.6 Removing and installing oil spray jets
  86
• Cylinder head, valve gear
  88
• 1 Cylinder head
  88
• 1.1 Assembly overview - cylinder head
  88
• 1.2 Assembly overview - camshaft housing
  90
• 1.3 Removing and installing cylinder head
  92
• 1.4 Removing and installing camshaft housing
  97
• 1.5 Checking compression
  101
• 2 Toothed belt drive
  104
• 2.1 Assembly overview - toothed belt cover
  104
• 2.2 Assembly overview - toothed belt
  104
• 2.3 Removing and installing toothed belt guard
  106
• 2.4 Removing and installing toothed belt
  107
• 2.5 Checking valve timing
  113
• 2.6 Adjusting valve timing
  121
• 2.7 Removing toothed belt from camshaft
  128
• 3 Valve gear
  133
• 3.1 Assembly overview - valve gear
  133
• 3.2 Measuring axial play of camshaft
  134
• 3.3 Removing and installing camshaft oil seal
  135
• 3.4 Removing and installing camshaft adjuster
  142
• 3.5 Removing and installing camshaft control valve 1 N205
  145
• 3.6 Removing and installing valve stem seals
  146
• 3.7 Removing and installing toothed belt pulley
  156
• 4 Inlet and exhaust valves
  159
• 4.1 Checking valve guides
  159
• 4.2 Checking valves
  160
• 4.3 Valve dimensions
  160
• Lubrication
  161
• 1 Sump, oil pump
  161
• 1.1 Assembly overview - sump/oil pump
  161
• 1.2 Engine oil:
  165
• 1.3 Removing and installing oil sump
  166
• 1.4 Removing and installing oil pump
  171
• 1.5 Removing and installing oil level and oil temperature sender G266
  174
• 2 Engine oil cooler
  175
• 2.1 Assembly overview - engine oil cooler
  175
• 2.2 Removing and installing engine oil cooler
  175
• 3 Crankcase ventilation
  177
• 3.1 Assembly overview - crankcase breather system
  177
• 3.2 Removing and installing oil separator
  178
• 4 Oil filter, oil pressure switch
  182
• 4.1 Assembly overview - oil filter/oil pressure switch
  182
• 4.2 Removing and installing oil pressure switch for reduced oil pressure F378
  182
• 4.3 Checking oil pressure and oil pressure switch
  183
• 4.4 Removing and installing oil filter housing
  185
• Cooling
  187
• 1 Cooling system/coolant
  187
• 1.1 Connection diagram - coolant hoses
  187
• 1.2 Checking cooling system for leaks
  189
• 1.3 Draining and adding coolant
  191
• 2 Coolant pump, regulation of cooling system
  201
• 2.1 Assembly overview - coolant pump, thermostat
  201
• 2.2 Assembly overview - electric coolant pump
  204
• 2.3 Assembly overview - coolant temperature sender
  205
• 2.4 Removing and installing electric coolant pump
  206
• 2.5 Removing and installing coolant pump
  208
• 2.6 Removing and installing thermostat
  214
• 2.7 Removing and installing toothed belt pulley for coolant pump
  217
• 2.8 Removing and installing coolant temperature sender G62
  219
• 2.9 Removing and installing radiator outlet coolant temperature sender G83
  220
• 3 Coolant pipes
  222
• 3.1 Assembly overview - coolant pipes
  222
• 3.2 Removing and installing coolant pipes
  222
• 4 Radiator, radiator fan
  226
• 4.1 Assembly overview - radiator, radiator fan
  226
• 4.2 Assembly overview – radiator cowl and radiator fan
  228
• 4.3 Removing and installing radiator
  229
• 4.4 Removing and installing water radiator for charge air cooling circuit
  230
• 4.5 Removing and installing radiator cowl
  233
• 4.6 Removing and installing radiator fan
  235
• Turbocharging/supercharging
  238
• 1 Turbocharger
  238
• 1.1 Assembly overview - turbocharger
  238
• 1.2 Removing and installing turbocharger
  240
• 1.3 Removing and installing charge pressure positioner V465
  244
• 2 Charge air system
  246
• 2.1 Assembly overview - charge air system
  246
• 2.2 Removing and installing charge air cooler
  249
• 2.3 Removing and installing charge pressure sender GX26
  252
• 2.4 Checking charge air system for leaks
  252
• 2.5 Removing and installing air pipe
  254
• Mixture preparation - injection
  256
• 1 Injection system
  256
• 1.1 Overview of fitting locations - injection system
  256
• 2 Injectors
  260
• 2.1 Assembly overview - fuel rail with injectors
  260
• 2.2 Removing and installing fuel rail
  261
• 2.3 Removing and installing injectors
  261
• 2.4 Cleaning injectors
  268
• 3 Air filter
  269
• 3.1 Assembly overview - air filter housing
  269
• 3.2 Removing and installing air filter housing
  270
• 3.3 Removing and installing resonator for intake air
  272
• 4 Intake manifold
  274
• 4.1 Assembly overview – intake manifold
  274
• 4.2 Removing and installing intake manifold
  276
• 4.3 Removing and installing throttle valve module GX3
  279
• 4.4 Cleaning throttle valve module GX3
  280
• 5 Senders and sensors
  282
• 5.1 Removing and installing intake manifold sender GX9
  282
• 5.2 Removing and installing fuel pressure sender G247
  282
• 5.3 Checking fuel pressure sender G247
  284
• 6 Engine control unit
  287
• 6.1 Removing and installing engine control unit J623
  287
• 7 High-pressure pump
  291
• 7.1 Assembly overview - high-pressure pump
  291
• 7.2 Removing and installing high-pressure pump
  295
• 7.3 Removing and installing high-pressure pipe
  297
• 8 Lambda probe
  300
• 8.1 Assembly overview - Lambda probe
  300
• 8.2 Removing and installing Lambda probe
  301
• Exhaust system
  305
• 1 Exhaust pipes and silencers
  305
• 1.1 Assembly overview – silencers
  305
• 1.2 Separating exhaust pipes from silencers
  308
• 1.3 Removing and installing rear silencer
  310
• 1.4 Aligning exhaust system free of stress
  311
• 1.5 Checking exhaust system for leaks
  312
• 1.6 Installation position of clamp
  312
• 2 Emission control
  315
• 2.1 Assembly overview – emission control
  315
• 2.2 Removing and installing catalytic converter
  317
• Ignition system
  322
• 1 Ignition system
  322
• 1.1 Assembly overview - ignition system
  322
• 1.2 Test data, spark plugs
  324
• 1.3 Removing and installing ignition coils with output stage
  324
• 1.4 Removing and installing knock sensor 1 G61
  327
• 1.5 Removing and installing Hall sender G40
  327
• 1.6 Removing and installing engine speed sender G28
  328