4-cylinder injection engine (1.2 l direct injection engine, 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
• 1.6 Safety precautions when working on exhaust system
  3
• 2 Identification
  4
• 2.1 Engine number/engine data
  4
• 3 Repair instructions
  6
• 3.1 Rules for cleanliness
  6
• 3.2 General information
  7
• 3.3 Foreign objects in engine
  7
• 3.4 Contact corrosion
  8
• 3.5 Routing and attachment of lines
  8
• 3.6 Fitting radiator and condensers
  8
• 3.7 Checking vacuum system
  8
• Removing and installing engine
  10
• 1 Removing and installing engine
  10
• 1.1 Removing engine
  10
• 1.2 Separating engine and gearbox
  20
• 1.3 Securing engine on engine and gearbox support
  24
• 1.4 Installing engine
  26
• 2 Assembly mountings
  31
• 2.1 Assembly overview - assembly mountings
  31
• 2.2 Removing and installing engine mounting
  33
• 2.3 Removing and installing gearbox mounting
  35
• 2.4 Removing and installing pendulum support
  36
• 2.5 Supporting engine in installation position
  38
• 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 Assembly overview - sealing flange, belt pulley end
  49
• 1.3 Removing and installing poly-V belt
  51
• 1.4 Removing and installing tensioner for poly V-belt
  54
• 1.5 Removing and installing vibration damper
  55
• 1.6 Removing and installing engine support
  57
• 1.7 Renewing crankshaft oil seal - belt pulley end
  60
• 1.8 Removing and installing sealing flange on pulley end
  63
• 2 Cylinder block, gearbox end
  64
• 2.1 Assembly overview - cylinder block, gearbox end
  64
• 2.2 Removing and installing flywheel
  65
• 2.3 Removing and installing sealing flange on gearbox side
  66
• 3 Crankshaft
  77
• 3.1 Crankshaft dimensions
  77
• 3.2 Renewing needle bearing in crankshaft
  77
• 3.3 Measuring axial clearance of crankshaft
  80
• 4 Pistons and conrods
  82
• 4.1 Assembly overview - pistons and conrods
  82
• 4.2 Removing and installing pistons
  85
• 4.3 Checking pistons and cylinder bores
  86
• 4.4 Separating new conrod
  88
• 4.5 Checking radial clearance of conrods
  89
• 4.6 Removing and installing oil spray jets
  89
• Cylinder head, valve gear
  91
• 1 Cylinder head
  91
• 1.1 Assembly overview - cylinder head
  91
• 1.2 Assembly overview - camshaft housing
  94
• 1.3 Removing and installing cylinder head
  97
• 1.4 Removing and installing camshaft housing
  102
• 1.5 Checking compression
  106
• 2 Toothed belt drive
  109
• 2.1 Assembly overview - toothed belt cover
  109
• 2.2 Assembly overview - toothed belt
  109
• 2.3 Removing and installing toothed belt
  111
• 2.4 Checking valve timing
  119
• 2.5 Removing toothed belt from camshaft
  125
• 3 Valve gear
  133
• 3.1 Assembly overview - valve gear
  133
• 3.2 Measuring axial play of camshaft
  135
• 3.3 Removing and installing camshaft oil seal
  136
• 3.4 Removing and installing camshaft adjuster
  144
• 3.5 Removing and installing camshaft control valve 1 N205
  146
• 3.6 Removing and installing valve stem seals
  146
• 4 Inlet and exhaust valves
  156
• 4.1 Reworking valve seats
  156
• 4.2 Checking valve guides
  158
• 4.3 Checking valves
  159
• 4.4 Valve dimensions
  159
• Lubrication
  160
• 1 Sump, oil pump
  160
• 1.1 Assembly overview - sump/oil pump
  160
• 1.2 Engine oil:
  164
• 1.3 Removing and installing oil sump
  165
• 1.4 Removing and installing oil pump
  171
• 1.5 Removing and installing oil level and oil temperature sender G266
  173
• 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
  183
• 4.3 Checking oil pressure and oil pressure switch
  184
• Cooling
  186
• 1 Cooling system/coolant
  186
• 1.1 Connection diagram - coolant hoses
  186
• 1.2 Checking cooling system for leaks
  188
• 1.3 Draining and adding coolant
  190
• 2 Coolant pump, regulation of cooling system
  197
• 2.1 Assembly overview - coolant pump, thermostat
  197
• 2.2 Assembly overview - electric coolant pump
  200
• 2.3 Assembly overview - coolant temperature sender
  201
• 2.4 Removing and installing electric coolant pump
  202
• 2.5 Removing and installing coolant pump
  204
• 2.6 Removing and installing thermostat
  209
• 2.7 Removing and installing toothed belt pulley for coolant pump
  213
• 2.8 Removing and installing coolant temperature sender G62
  215
• 2.9 Removing and installing radiator outlet coolant temperature sender G83
  217
• 3 Coolant pipes
  219
• 3.1 Assembly overview - coolant pipes
  219
• 3.2 Removing and installing coolant pipes
  219
• 4 Radiator, radiator fan
  224
• 4.1 Assembly overview - radiator/radiator fan
  224
• 4.2 Assembly overview – radiator cowl and radiator fan
  226
• 4.3 Removing and installing radiator
  227
• 4.4 Removing and installing radiator cowl with radiator fan
  231
• 4.5 Removing and installing radiator fan VX57
  232
• 4.6 Removing and installing radiator fan 2 V177
  233
• Turbocharging/supercharging
  234
• 1 Turbocharger
  234
• 1.1 Assembly overview - turbocharger
  234
• 1.2 Removing and installing turbocharger
  235
• 1.3 Removing and installing charge pressure positioner V465
  239
• 2 Charge air system
  241
• 2.1 Assembly overview - charge air system
  241
• 2.2 Removing and installing charge air cooler
  244
• 2.4 Checking charge air system for leaks
  247
• 2.5 Removing and installing air pipe
  250
• Mixture preparation - injection
  253
• 1 Injection system
  253
• 1.1 Overview of fitting locations - injection system
  253
• 2 Injectors
  257
• 2.1 Assembly overview - fuel rail with injectors
  257
• 2.2 Removing and installing fuel rail
  259
• 2.3 Removing and installing injectors
  259
• 2.4 Renewing seals on injectors
  264
• 2.5 Cleaning injectors
  271
• 3 Air filter
  273
• 3.1 Assembly overview - air filter housing
  273
• 3.2 Removing and installing air filter housing
  275
• 4 Intake manifold
  276
• 4.1 Assembly overview – intake manifold
  276
• 4.2 Removing and installing intake manifold
  278
• 4.3 Removing and installing throttle valve module GX3
  280
• 4.4 Cleaning throttle valve module
  281
• 5 Senders and sensors
  283
• 5.1 Removing and installing fuel pressure sender G247
  283
• 5.2 Checking fuel pressure sender G247
  284
• 6 Engine control unit
  287
• 6.1 Removing and installing engine (motor) control unit J623 with protective housing
  287
• 7 High-pressure pump
  290
• 7.1 Assembly overview - high-pressure pump
  290
• 7.2 Removing and installing high-pressure pump
  291
• 7.3 Removing and installing high-pressure pipe
  292
• 8 Lambda probe
  294
• 8.1 Assembly overview - Lambda probe
  294
• 8.2 Removing and installing Lambda probe
  295
• Exhaust system
  297
• 1 Exhaust pipes and silencers
  297
• 1.1 Assembly overview – silencers
  297
• 1.2 Separating exhaust pipes from silencers
  298
• 1.3 Aligning exhaust system free of stress
  300
• 1.4 Checking exhaust system for leaks
  301
• 1.5 Installation position of clamp
  301
• 2 Emission control
  304
• 2.1 Assembly overview – emission control
  304
• 2.2 Removing and installing catalytic converter
  307
• Ignition system
  311
• 1 Ignition system
  311
• 1.1 Assembly overview - ignition system
  311
• 1.2 Test data, spark plugs
  312
• 1.3 Removing and installing ignition coils with output stage
  313
• 1.4 Removing and installing knock sensor 1 G61
  315
• 1.5 Removing and installing Hall sender G40
  317
• 1.6 Removing and installing engine speed sender G28
  317