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
  23
• 2 Assembly mountings
  27
• 2.1 Assembly overview - assembly mountings
  27
• 2.2 Removing and installing engine mounting
  30
• 2.3 Removing and installing gearbox mounting
  32
• 2.4 Removing and installing pendulum support
  33
• 2.5 Supporting engine in installation position
  34
• 2.6 Adjusting assembly mountings
  43
• 2.7 Checking adjustment of assembly mountings
  45
• Crankshaft group
  46
• 1 Cylinder block (pulley end)
  46
• 1.1 Assembly overview - poly V-belt drive
  46
• 1.2 Assembly overview - sealing flange, belt pulley end
  50
• 1.3 Removing and installing poly-V belt
  52
• 1.4 Removing and installing tensioner for poly V-belt
  56
• 1.5 Removing and installing vibration damper
  57
• 1.6 Removing and installing engine support
  58
• 1.7 Renewing crankshaft oil seal - belt pulley end
  61
• 1.8 Removing and installing sealing flange on pulley end
  64
• 2 Cylinder block, gearbox end
  67
• 2.1 Assembly overview - cylinder block, gearbox end
  67
• 2.2 Removing and installing flywheel
  68
• 2.3 Removing and installing sealing flange on gearbox side
  69
• 3 Crankshaft
  80
• 3.1 Crankshaft dimensions
  80
• 3.2 Renewing needle bearing in crankshaft
  80
• 3.3 Measuring axial clearance of crankshaft
  83
• 4 Pistons and conrods
  85
• 4.1 Assembly overview - pistons and conrods
  85
• 4.2 Removing and installing pistons
  88
• 4.3 Checking pistons and cylinder bores
  89
• 4.4 Separating new conrod
  91
• 4.5 Checking radial clearance of conrods
  92
• 4.6 Removing and installing oil spray jets
  92
• Cylinder head, valve gear
  95
• 1 Cylinder head
  95
• 1.1 Assembly overview - cylinder head
  95
• 1.2 Assembly overview - camshaft housing
  97
• 1.3 Removing and installing cylinder head
  99
• 1.4 Removing and installing camshaft housing
  104
• 1.5 Checking compression
  109
• 2 Toothed belt drive
  112
• 2.1 Assembly overview - toothed belt cover
  112
• 2.2 Assembly overview - toothed belt
  112
• 2.3 Removing and installing toothed belt guard
  114
• 2.4 Removing and installing toothed belt
  115
• 2.5 Checking valve timing
  122
• 2.6 Adjusting valve timing
  128
• 2.7 Removing toothed belt from camshaft
  137
• 3 Valve gear
  142
• 3.1 Assembly overview - valve gear
  142
• 3.2 Measuring axial play of camshaft
  143
• 3.3 Removing and installing camshaft oil seal
  144
• 3.4 Removing and installing camshaft adjuster
  150
• 3.5 Removing and installing camshaft control valve 1 N205
  162
• 3.6 Removing and installing exhaust camshaft control valve 1 N318
  163
• 3.7 Removing and installing valve stem seals
  164
• 4 Inlet and exhaust valves
  175
• 4.1 Checking valve guides
  175
• 4.2 Checking valves
  176
• 4.3 Valve dimensions
  176
• Lubrication
  177
• 1 Sump, oil pump
  177
• 1.1 Assembly overview - sump/oil pump
  177
• 1.2 Engine oil:
  181
• 1.3 Removing and installing lower part of sump
  181
• 1.4 Removing and installing upper part of sump
  186
• 1.5 Removing and installing oil pump
  193
• 1.6 Removing and installing oil level and oil temperature sender G266
  194
• 2 Engine oil cooler
  196
• 2.1 Assembly overview - engine oil cooler
  196
• 2.2 Removing and installing engine oil cooler
  196
• 3 Crankcase ventilation
  198
• 3.1 Assembly overview - crankcase breather system
  198
• 3.2 Removing and installing oil separator
  199
• 4 Oil filter, oil pressure switch
  203
• 4.1 Assembly overview - oil filter/oil pressure switch
  203
• 4.2 Removing and installing oil pressure switch F1
  204
• 4.3 Removing and installing oil pressure switch for reduced oil pressure F378
  205
• 4.4 Checking oil pressure
  206
• 4.5 Removing and installing oil pressure regulating valve N428
  208
• Cooling
  209
• 1 Cooling system/coolant
  209
• 1.1 Connection diagram - coolant hoses
  209
• 1.2 Assembly overview - engine preheater
  210
• 1.3 Checking cooling system for leaks
  211
• 1.4 Draining and adding coolant
  214
• 1.5 Removing and installing engine preheating element Z97
  223
• 2 Coolant pump, regulation of cooling system
  226
• 2.1 Assembly overview - coolant pump, thermostat
  226
• 2.2 Assembly overview - electric coolant pump
  229
• 2.3 Assembly overview - coolant temperature sender
  230
• 2.4 Removing and installing electric coolant pump
  231
• 2.5 Removing and installing coolant pump
  233
• 2.6 Removing and installing thermostat
  239
• 2.7 Removing and installing toothed belt pulley for coolant pump
  242
• 2.8 Removing and installing coolant temperature sender G62
  244
• 2.9 Removing and installing radiator outlet coolant temperature sender G83
  245
• 3 Coolant pipes
  247
• 3.1 Assembly overview - coolant pipes
  247
• 3.2 Removing and installing coolant pipes
  247
• 4 Radiator, radiator fan
  252
• 4.1 Assembly overview - radiator/radiator fan
  252
• 4.2 Assembly overview – radiator cowl and radiator fan
  254
• 4.3 Removing and installing radiator
  255
• 4.4 Removing and installing water radiator for charge air cooling circuit
  257
• 4.5 Removing and installing radiator cowl
  260
• 4.6 Removing and installing radiator fan V7
  262
• 4.7 Removing and installing radiator fan 2 V177
  263
• Turbocharging/supercharging
  264
• 1 Turbocharger
  264
• 1.1 Assembly overview - turbocharger
  264
• 1.2 Removing and installing turbocharger
  268
• 1.3 Removing and installing charge pressure positioner V465
  274
• 2 Charge air system
  279
• 2.1 Assembly overview - charge air system
  279
• 2.2 Removing and installing charge air cooler
  282
• 2.3 Removing and installing charge pressure sender GX26
  285
• 2.4 Checking charge air system for leaks
  285
• 2.5 Removing and installing air pipe
  287
• Mixture preparation - injection
  289
• 1 Injectors
  289
• 1.1 Assembly overview - fuel rail with injectors
  289
• 1.2 Removing and installing fuel rail
  291
• 1.3 Removing and installing injectors
  291
• 1.4 Cleaning injectors
  297
• 2 Air filter
  299
• 2.1 Assembly overview - air filter housing
  299
• 2.2 Removing and installing air filter housing
  300
• 2.3 Removing and installing resonator for intake air
  301
• 3 Intake manifold
  303
• 3.1 Assembly overview – intake manifold
  303
• 3.2 Removing and installing intake manifold
  305
• 3.3 Removing and installing throttle valve module GX3
  309
• 3.4 Cleaning throttle valve module GX3
  310
• 4 Senders and sensors
  312
• 4.1 Removing and installing fuel pressure sender G247
  312
• 4.2 Checking fuel pressure sender G247
  313
• 4.3 Removing and installing intake manifold sender GX9
  315
• 5 Engine control unit
  317
• 5.1 Removing and installing engine control unit J623
  317
• 6 High-pressure pump
  322
• 6.1 Assembly overview - high-pressure pump
  322
• 6.2 Removing and installing high-pressure pump
  326
• 6.3 Removing and installing high-pressure pipe
  328
• 7 Lambda probe
  331
• 7.1 Assembly overview - Lambda probe
  331
• 7.2 Removing and installing Lambda probe
  332
• Exhaust system
  336
• 1 Exhaust pipes and silencers
  336
• 1.1 Assembly overview – silencers
  336
• 1.2 Separating exhaust pipes from silencers
  339
• 1.3 Removing and installing rear silencer
  341
• 1.4 Aligning exhaust system free of stress
  342
• 1.5 Checking exhaust system for leaks
  343
• 1.6 Installation position of clamp
  343
• 2 Emission control
  346
• 2.1 Assembly overview – emission control
  346
• 2.2 Removing and installing catalytic converter
  348
• Ignition system
  354
• 1 Ignition system
  354
• 1.1 Assembly overview - ignition system
  354
• 1.2 Test data, spark plugs
  356
• 1.3 Removing and installing ignition coils with output stage
  356
• 1.4 Removing and installing knock sensor 1 G61
  359
• 1.5 Removing and installing Hall sender
  359
• 1.6 Removing and installing engine speed sender G28
  360