4-cylinder injection engine (1.2 l direct injection engine, EA111, turbocharger)

Chapter overview

• Technical data
  1
• 1 Identification
  1
• 1.1 Engine number/engine data
  1
• 2 General information
  3
• 2.1 Numbering of cylinders
  3
• 3 Safety information
  4
• 3.1 Safety precautions when working on fuel system
  4
• 3.3 Safety precautions when working on the cooling system
  5
• 3.4 Safety precautions when working on ignition system
  6
• 3.5 Releasing high pressure in fuel system
  7
• 4 Repair instructions
  8
• 4.1 Rules for cleanliness
  8
• 4.2 Foreign objects in engine
  8
• Removing and installing engine
  9
• 1 Removing and installing engine
  9
• 1.1 Removing engine
  9
• 1.2 Separating engine and gearbox
  20
• 1.3 Securing engine on engine and gearbox support
  22
• 1.4 Installing engine
  24
• 2 Assembly mountings
  27
• 2.1 Assembly overview - assembly mountings
  27
• 2.2 Removing and installing engine mounting
  29
• 2.3 Supporting engine in installation position
  37
• 2.4 Adjusting assembly mountings
  45
• 2.5 Checking adjustment of assembly mountings
  47
• Crankshaft group
  48
• 1 Cylinder block (pulley end)
  48
• 1.1 Assembly overview - cylinder block (pulley end)
  48
• 1.2 Assembly overview - poly V-belt drive
  52
• 1.3 Removing and installing poly-V belt
  57
• 1.4 Removing and installing tensioner for poly V-belt
  60
• 1.5 Removing and installing vibration damper
  63
• 1.6 Removing and installing bracket for ancillaries
  67
• 1.7 Renewing crankshaft oil seal - belt pulley end
  70
• 2 Cylinder block, gearbox end
  74
• 2.1 Assembly overview - cylinder block, gearbox end
  74
• 2.2 Removing and installing sealing flange on gearbox side
  76
• 3 Crankshaft
  87
• 3.1 Crankshaft dimensions
  87
• 3.2 Renewing needle bearing in crankshaft
  87
• 4 Pistons and conrods
  89
• 4.1 Assembly overview - pistons and conrods
  89
• 4.2 Checking pistons and cylinder bores
  91
• 4.3 Separating new conrod
  93
• Cylinder head, valve gear
  95
• 1 Cylinder head
  95
• 1.1 Assembly overview - cylinder head
  95
• 1.2 Removing and installing cylinder head
  98
• 1.3 Removing and installing cylinder head cover
  109
• 1.4 Checking compression
  122
• 2 Cover for timing chain
  124
• 2.1 Removing and installing valve timing housing (timing case)
  124
• 3 Chain drive
  132
• 3.1 Removing and installing camshaft timing chain
  132
• 3.2 Removing and installing timing chain and chain drive for oil pump
  140
• 3.3 Checking valve timing
  141
• 3.4 Adjusting valve timing
  144
• 4 Valve gear
  154
• 4.1 Assembly overview - valve gear
  154
• 4.2 Measuring axial play of camshaft
  160
• 4.3 Removing and installing camshaft
  161
• 4.4 Removing and installing valve stem seals
  163
• Lubrication
  166
• 1 Sump, oil pump
  166
• 1.1 Assembly overview - sump/oil pump
  166
• 1.2 Engine oil:
  169
• 1.3 Removing and installing sump
  170
• 1.4 Removing and installing oil pump
  173
• 2 Engine oil cooler
  175
• 2.1 Removing and installing engine oil cooler
  175
• 3 Oil filter, oil pressure switch
  176
• 3.1 Checking oil pressure and oil pressure switch
  176
• Cooling
  178
• 1 Cooling system/coolant
  178
• 1.1 Connection diagram - coolant hoses
  178
• 1.2 Checking cooling system for leaks
  178
• 1.3 Draining and adding coolant
  181
• 2 Coolant pump, regulation of cooling system
  188
• 2.1 Assembly overview - thermostat
  188
• 2.2 Removing and installing coolant pump
  188
• 2.3 Removing and installing coolant pump pulley
  190
• 2.4 Removing and installing electric coolant pump
  192
• 3 Radiator, radiator fan
  195
• 3.1 Assembly overview - radiator/radiator fan
  195
• 3.2 Removing and installing radiator
  197
• 3.3 Removing and installing radiator cowl
  199
• 3.4 Removing and installing radiator fan
  201
• Turbocharging/supercharging
  202
• 1 Turbocharger
  202
• 1.1 Assembly overview - turbocharger
  202
• 1.2 Removing and installing turbocharger
  206
• 1.3 Removing and installing charge pressure positioner V465
  211
• 2 Charge air system
  214
• 2.1 Assembly overview - charge air system
  214
• 2.2 Removing and installing charge air cooler
  216
• Mixture preparation - injection
  219
• 1 Injection system
  219
• 2 Injectors
  220
• 2.1 Removing and installing injectors
  220
• 2.2 Renewing seals on injectors
  223
• 2.3 Cleaning injectors
  227
• 3 Air filter
  229
• 3.1 Assembly overview - air filter housing
  229
• 3.2 Removing and installing air filter housing
  230
• 4 Intake manifold
  232
• 4.1 Assembly overview – intake manifold
  232
• 4.2 Removing and installing intake manifold
  238
• 4.3 Removing and installing throttle valve module J338
  241
• 4.4 Cleaning throttle valve module
  243
• 5 Senders and sensors
  245
• 5.1 Checking fuel pressure sender G247
  245
• 6 Engine control unit
  249
• 6.1 Removing and installing engine control unit J623
  249
• 7 High-pressure pump
  252
• 7.1 Assembly overview - high-pressure pump
  252
• 7.2 Removing and installing high-pressure pump
  253
• Exhaust system
  257
• 1 Exhaust pipes and silencers
  257
• 1.1 Assembly overview – silencers
  257
• 1.2 Separating exhaust pipes from silencers
  257
• 1.3 Installation position of clamp
  259
• 2 Emission control
  262
• 2.1 Assembly overview – emission control
  262
• Ignition system
  265
• 1 Ignition system
  265
• 1.1 Assembly overview - ignition system
  265
• 1.2 Removing and installing engine speed sender G28
  267
• 1.3 Test data, spark plugs
  267