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

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety precautions when working on the cooling system
  1
• 1.2 Safety regulations for working on fuel supply
  2
• 1.3 Releasing high pressure in fuel system
  2
• 1.4 Safety precautions when working on charge air system
  3
• 1.5 Safety precautions when working on ignition system
  3
• 1.6 Safety regulations for working on fuel supply
  4
• 2 Identification
  6
• 2.1 Engine number/engine data
  6
• 3 General information
  7
• 3.1 General notes on injection
  7
• 4 Repair instructions
  8
• 4.1 Rules for cleanliness when working on fuel supply system/injection system
  8
• Removing and installing engine
  9
• 1 Removing and installing engine
  9
• 1.1 Removing engine
  9
• 1.2 Securing engine on engine and gearbox support
  16
• 1.3 Installing engine
  16
• 2 Assembly mountings
  20
• 2.1 Assembly overview - assembly mountings
  20
• Crankshaft group
  21
• 1 Cylinder block (pulley end)
  21
• 1.1 Assembly overview - poly V-belt drive
  21
• 1.2 Removing and installing poly V-belt, vehicles with air conditioner
  22
• 1.3 Removing and installing poly V-belt, vehicles without air conditioner
  23
• 1.4 Removing and installing top ancillary bracket
  24
• 1.5 Removing and installing bottom ancillary bracket
  25
• 1.6 Renewing crankshaft oil seal - belt pulley end
  26
• 1.7 Removing and installing belt pulley
  29
• 2 Cylinder block, gearbox end
  33
• 2.1 Assembly overview - cylinder block, gearbox end
  33
• 2.2 Removing and installing sealing flange on gearbox side
  34
• 3 Crankshaft
  43
• 3.1 Renewing needle bearing in crankshaft
  43
• 3.2 Crankshaft dimensions
  44
• 4 Pistons and conrods
  45
• 4.1 Assembly overview - pistons and conrods
  45
• 4.2 Checking pistons and cylinder bores
  46
• 4.3 Separating new conrod
  47
• 4.4 Piston and cylinder dimensions
  48
• Cylinder head, valve gear
  49
• 1 Cylinder head
  49
• 1.1 Assembly overview - cylinder head
  49
• 1.2 Removing and installing cylinder head cover with camshaft
  51
• 1.3 Removing and installing cylinder head
  60
• 1.4 Checking compression
  66
• 2 Cover for timing chain
  68
• 2.1 Removing and installing top valve timing housing
  68
• 2.2 Removing and installing bottom valve timing housing
  71
• 3 Chain drive
  74
• 3.1 Assembly overview - timing chain
  74
• 3.2 Checking timing chain
  77
• 3.3 Removing and installing timing chain
  80
• 3.4 Removing and installing timing chain and chain drive for oil pump
  87
• 3.5 Checking valve timing
  90
• 3.6 Adjusting valve timing
  93
• 4 Valve gear
  101
• 4.1 Assembly overview - valve gear
  101
• 4.2 Measuring axial play of camshaft
  102
• 4.3 Removing and installing valve stem seals
  103
• 5 Inlet and exhaust valves
  105
• 5.1 Reworking valve seats
  105
• 5.2 Checking valve guides
  106
• 5.3 Valve dimensions
  107
• Lubrication
  108
• 1 Sump, oil pump
  108
• 1.1 Assembly overview - sump/oil pump
  108
• 1.2 Engine oil:
  111
• 1.3 Removing and installing oil sump
  111
• 1.4 Removing and installing oil pump
  115
• 2 Engine oil cooler
  118
• 2.1 Removing and installing engine oil cooler
  118
• 3 Crankcase ventilation
  120
• 3.1 Assembly overview - crankcase breather system
  120
• 3.2 Removing and installing oil separator
  121
• 4 Oil filter, oil pressure switch
  123
• 4.1 Checking oil pressure and oil pressure switch
  123
• 4.2 Removing and installing non-return valve
  124
• Cooling
  126
• 1 Cooling system/coolant
  126
• 1.1 Connection diagram - coolant hoses
  126
• 1.2 Draining and adding coolant
  127
• 1.3 Checking cooling system for leaks
  132
• 2 Coolant pump, regulation of cooling system
  134
• 2.1 Assembly overview - thermostat
  134
• 2.2 Removing and installing coolant pump
  134
• 2.3 Removing and installing coolant circulation pump V50
  136
• 3 Radiator, radiator fan
  139
• 3.1 Assembly overview - radiator/ radiator fan V7
  139
• 3.2 Removing and installing radiator
  141
• 3.3 Removing and installing radiator fan V7
  143
• Turbocharging/supercharging
  145
• 1 Exhaust turbocharger
  145
• 1.1 Assembly overview - turbocharger
  145
• 1.2 Removing and installing turbocharger
  147
• 1.3 Removing and installing charge pressure positioner V465
  150
• 2 Charge air system
  153
• 2.1 Assembly overview - charge air system
  153
• 2.2 Removing and installing charge air cooler
  154
• Mixture preparation - injection
  157
• 1 Injectors
  157
• 1.1 Removing and installing injectors
  157
• 1.2 Renewing seals on injectors
  159
• 2 Air filter
  163
• 2.1 Assembly overview - air filter
  163
• 2.2 Removing and installing air filter
  163
• 3 Intake manifold
  165
• 3.1 Assembly overview - intake manifold, part I
  165
• 3.2 Assembly overview - intake manifold, part II
  166
• 3.3 Removing and installing intake manifold
  167
• 3.4 Removing and installing throttle valve module J338
  168
• 3.5 Cleaning throttle valve module J338
  171
• 4 Senders and sensors
  172
• 4.1 Checking fuel pressure sender G247
  172
• 4.2 Checking fuel pressure regulator and holding pressure
  174
• 5 Engine (motor) control unit
  178
• 5.1 Removing and installing engine (motor) control unit J623
  178
• 5.2 Removing and installing anti-theft engine control unit J623
  179
• 6 High-pressure pump
  181
• 6.1 Assembly overview - high-pressure pump
  181
• 6.2 Removing and installing high-pressure pump
  182
• Exhaust system
  185
• 1 Exhaust pipes and silencers
  185
• 1.1 Assembly overview - silencers
  185
• 1.2 Separating exhaust pipes from silencers
  186
• 1.3 Installation position of clamp
  187
• 2 Exhaust gas cleaning
  189
• 2.1 Assembly overview - emission control
  189
• 2.2 Assembly overview- emission control, vehicles as of week 22/2011
  191
• Ignition system
  193
• 1 Ignition system
  193
• 1.1 Assembly overview - ignition system
  193
• 1.2 Test data, spark plugs
  194
• 1.3 Removing and installing engine speed sender G28
  195