4-cylinder injection engine (1.4 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
  5
• 3.1 Rules for cleanliness
  5
• 3.2 Foreign objects in engine
  5
• 3.3 Contact corrosion
  5
• 3.4 Routing and attachment of lines
  5
• 3.5 Fitting radiator and condensers
  6
• Removing and installing engine
  7
• 1 Removing and installing engine
  7
• 1.1 Removing engine
  7
• 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
  28
• 2.1 Assembly overview - assembly mountings
  28
• 2.2 Removing and installing engine mounting
  31
• 2.3 Removing and installing gearbox mounting
  33
• 2.4 Removing and installing pendulum support
  34
• 2.5 Supporting engine in installation position
  35
• 2.6 Adjusting assembly mountings
  44
• 2.7 Checking adjustment of assembly mountings
  47
• Crankshaft group
  48
• 1 Cylinder block (pulley end)
  48
• 1.1 Assembly overview - poly V-belt drive
  48
• 1.2 Assembly overview - sealing flange, belt pulley end
  52
• 1.3 Removing and installing poly-V belt
  54
• 1.4 Removing and installing tensioner for poly V-belt
  58
• 1.5 Removing and installing vibration damper
  59
• 1.6 Removing and installing engine support
  61
• 1.7 Renewing crankshaft oil seal - belt pulley end
  64
• 1.8 Removing and installing sealing flange on pulley end
  67
• 2 Cylinder block, gearbox end
  70
• 2.1 Assembly overview - cylinder block, gearbox end
  70
• 2.2 Assembly overview - drive plate
  71
• 2.3 Removing and installing drive plate
  72
• 2.4 Removing and installing flywheel
  74
• 2.5 Removing and installing sealing flange on gearbox side
  75
• 3 Crankshaft
  86
• 3.1 Crankshaft dimensions
  86
• 3.2 Renewing needle bearing in crankshaft
  86
• 3.3 Measuring axial clearance of crankshaft
  89
• 4 Pistons and conrods
  91
• 4.1 Assembly overview - pistons and conrods
  91
• 4.2 Removing and installing pistons
  94
• 4.3 Checking pistons and cylinder bores
  95
• 4.4 Separating new conrod
  97
• 4.5 Checking radial clearance of conrods
  98
• 4.6 Removing and installing oil spray jets
  98
• Cylinder head, valve gear
  101
• 1 Cylinder head
  101
• 1.1 Assembly overview - cylinder head
  101
• 1.2 Assembly overview - camshaft housing
  103
• 1.3 Removing and installing cylinder head
  107
• 1.4 Removing and installing camshaft housing
  112
• 1.5 Checking compression
  117
• 2 Toothed belt drive
  120
• 2.1 Assembly overview - toothed belt cover
  120
• 2.2 Assembly overview - toothed belt
  121
• 2.3 Removing and installing toothed belt guard
  125
• 2.4 Removing and installing toothed belt
  126
• 2.5 Checking valve timing
  140
• 2.6 Adjusting valve timing
  147
• 2.7 Removing toothed belt from camshaft
  164
• 3 Valve gear
  174
• 3.1 Assembly overview - valve gear
  174
• 3.2 Measuring axial play of camshaft
  176
• 3.3 Removing and installing camshaft oil seal
  177
• 3.4 Removing and installing camshaft adjuster
  183
• 3.5 Removing and installing camshaft control valve 1 N205
  200
• 3.6 Removing and installing exhaust camshaft control valve 1 N318
  201
• 3.7 Removing and installing valve stem seals
  202
• 3.8 Removing and installing toothed belt pulley
  212
• 4 Inlet and exhaust valves
  215
• 4.1 Checking valve guides
  215
• 4.2 Checking valves
  216
• 4.3 Valve dimensions
  216
• Lubrication
  217
• 1 Sump, oil pump
  217
• 1.1 Assembly overview - sump/oil pump
  217
• 1.2 Engine oil:
  221
• 1.3 Removing and installing lower part of sump
  221
• 1.4 Removing and installing upper part of sump
  226
• 1.5 Removing and installing oil pump
  233
• 1.6 Removing and installing oil level and oil temperature sender G266
  234
• 2 Engine oil cooler
  236
• 2.1 Assembly overview - engine oil cooler
  236
• 2.2 Removing and installing engine oil cooler
  236
• 3 Crankcase ventilation
  238
• 3.1 Assembly overview - crankcase breather system
  238
• 3.2 Removing and installing oil separator
  239
• 4 Oil filter, oil pressure switch
  243
• 4.1 Assembly overview - oil filter/oil pressure switch
  243
• 4.2 Removing and installing oil pressure switch F1
  244
• 4.3 Removing and installing oil pressure switch for reduced oil pressure F378
  245
• 4.4 Checking oil pressure
  246
• 4.5 Removing and installing oil pressure regulating valve N428
  248
• Cooling
  249
• 1 Cooling system/coolant
  249
• 1.1 Connection diagram - coolant hoses
  249
• 1.2 Assembly overview - engine preheater
  250
• 1.3 Checking cooling system for leaks
  251
• 1.4 Draining and adding coolant
  254
• 1.5 Removing and installing engine preheating element Z97
  263
• 2 Coolant pump, regulation of cooling system
  266
• 2.1 Assembly overview - coolant pump, thermostat
  266
• 2.2 Assembly overview - electric coolant pump
  269
• 2.3 Assembly overview - coolant temperature sender
  270
• 2.4 Removing and installing electric coolant pump
  271
• 2.5 Removing and installing coolant pump
  273
• 2.6 Removing and installing thermostat
  279
• 2.7 Removing and installing toothed belt pulley for coolant pump
  282
• 2.8 Removing and installing coolant temperature sender G62
  284
• 2.9 Removing and installing radiator outlet coolant temperature sender G83
  285
• 3 Coolant pipes
  287
• 3.1 Assembly overview - coolant pipes
  287
• 3.2 Removing and installing coolant pipes
  287
• 4 Radiator, radiator fan
  292
• 4.1 Assembly overview - radiator/radiator fan
  292
• 4.2 Assembly overview – radiator cowl and radiator fan
  294
• 4.3 Removing and installing radiator
  295
• 4.4 Removing and installing water radiator for charge air cooling circuit
  297
• 4.5 Removing and installing radiator cowl
  300
• 4.6 Removing and installing radiator fan V7
  302
• 4.7 Removing and installing radiator fan 2 V177
  303
• Turbocharging/supercharging
  304
• 1 Turbocharger
  304
• 1.1 Assembly overview - turbocharger
  304
• 1.2 Removing and installing turbocharger
  308
• 1.3 Removing and installing charge pressure positioner V465
  314
• 1.4 Removing and installing connection for turbocharger
  318
• 2 Charge air system
  322
• 2.1 Assembly overview - charge air system
  322
• 2.2 Removing and installing charge air cooler
  325
• 2.3 Removing and installing charge pressure sender GX26
  328
• 2.4 Checking charge air system for leaks
  329
• 2.5 Removing and installing air pipe
  330
• Mixture preparation - injection
  333
• 1 Injection system
  333
• 1.1 Overview of fitting locations - injection system
  333
• 2 Injectors
  338
• 2.1 Assembly overview - fuel rail with injectors
  338
• 2.2 Removing and installing fuel rail
  339
• 2.3 Removing and installing injectors
  339
• 2.4 Cleaning injectors
  346
• 3 Air filter
  348
• 3.1 Assembly overview - air filter housing
  348
• 3.2 Removing and installing air filter housing
  349
• 3.3 Removing and installing resonator for intake air
  350
• 4 Intake manifold
  352
• 4.1 Assembly overview – intake manifold
  352
• 4.2 Removing and installing intake manifold
  354
• 4.3 Removing and installing throttle valve module GX3
  358
• 4.4 Cleaning throttle valve module GX3
  359
• 5 Senders and sensors
  361
• 5.1 Removing and installing fuel pressure sender G247
  361
• 5.2 Checking fuel pressure sender G247
  362
• 5.3 Removing and installing intake manifold sender GX9
  364
• 6 Engine control unit
  366
• 6.1 Removing and installing engine control unit J623
  366
• 7 High-pressure pump
  371
• 7.1 Assembly overview - high-pressure pump
  371
• 7.2 Removing and installing high-pressure pump
  375
• 7.3 Removing and installing high-pressure pipe
  377
• 8 Lambda probe
  380
• 8.1 Assembly overview - Lambda probe
  380
• 8.2 Removing and installing Lambda probe
  382
• Exhaust system
  387
• 1 Exhaust pipes and silencers
  387
• 1.1 Assembly overview – silencers
  387
• 1.2 Separating exhaust pipes from silencers
  388
• 1.3 Removing and installing rear silencer
  389
• 1.4 Aligning exhaust system free of stress
  390
• 1.5 Checking exhaust system for leaks
  391
• 1.6 Installation position of clamp
  391
• 2 Emission control
  394
• 2.1 Assembly overview – emission control
  394
• 2.2 Removing and installing catalytic converter
  396
• Ignition system
  402
• 1 Ignition system
  402
• 1.1 Assembly overview - ignition system
  402
• 1.2 Test data, spark plugs
  404
• 1.3 Removing and installing ignition coils with output stage
  404
• 1.4 Removing and installing knock sensor 1 G61
  407
• 1.5 Removing and installing Hall sender
  407
• 1.6 Removing and installing engine speed sender G28
  408