4-cylinder injection engine (1.4 l direct injection EA 111 engine, turbocharger and supercharger)

Chapter overview

• Technical data
  1
• 1 Identification
  1
• 1.1 Engine number/engine data
  1
• 2 General notes
  3
• 2.1 Numbering of cylinders
  3
• 3 Safety information
  4
• 3.1 Safety regulations for working on fuel supply
  4
• 3.3 Safety precautions when working on the cooling system
  6
• 3.4 Safety precautions when working on ignition system
  7
• 3.5 Releasing high pressure in fuel system
  7
• 4 Repair notes
  9
• 4.1 Rules for cleanliness
  9
• 4.2 Foreign objects in engine
  9
• 4.3 Contact corrosion
  9
• 4.4 Pipe/wire routing and attachment
  9
• 4.5 Fitting radiator and condensers
  10
• Removing and installing engine
  11
• 1 Removing and installing engine
  11
• 1.1 Removing engine
  11
• 1.2 Separating engine and gearbox
  22
• 1.3 Securing engine on engine and gearbox support
  24
• 1.4 Installing engine
  25
• 2 Assembly mountings
  28
• 2.1 Assembly overview - assembly mountings
  28
• 2.2 Removing and installing motor mounting
  30
• 2.3 Supporting engine in installation position
  35
• 2.4 Adjusting assembly mountings
  41
• 2.5 Checking adjustment of assembly mountings (engine and gearbox mountings)
  43
• 3 Motor cover
  44
• 3.1 Removing and installing engine cover
  44
• Crankshaft group
  45
• 1 Cylinder block (pulley end)
  45
• 1.1 Assembly overview - cylinder block (pulley end)
  45
• 1.2 Assembly overview - poly V-belt drive
  48
• 1.3 Removing and installing poly-V belt
  50
• 1.4 Removing and installing vibration damper
  52
• 1.5 Removing and installing bracket for ancillaries
  56
• 1.6 Renewing crankshaft oil seal - belt pulley end
  57
• 2 Cylinder block, gearbox end
  61
• 2.1 Assembly overview - cylinder block, gearbox end
  61
• 2.2 Removing and installing sealing flange on gearbox side
  62
• 3 Crankshaft
  72
• 3.1 Assembly overview - crankshaft
  72
• 3.2 Renewing needle bearing in crankshaft
  73
• 3.3 Crankshaft dimensions
  75
• 4 Pistons and conrods
  76
• 4.1 Assembly overview - pistons and conrods
  76
• 4.2 Checking pistons and cylinder bores
  77
• 4.3 Separating new conrod
  78
• 4.4 Removing and installing pistons
  79
• 4.5 Removing and installing oil spray jets
  80
• Cylinder head, valve gear
  82
• 1 Cylinder head
  82
• 1.1 Assembly overview - cylinder head
  82
• 1.2 Removing and installing cylinder head
  84
• 1.3 Removing and installing camshaft housing
  87
• 1.4 Checking compression
  94
• 2 Cover for timing chain
  97
• 2.1 Removing and installing timing chain cover
  97
• 3 Chain drive
  102
• 3.1 Removing and installing timing chain and chain drive for oil pump
  102
• 3.2 Checking timing chain
  109
• 3.3 Checking valve timing
  116
• 3.4 Adjusting valve timing
  119
• 4 Valve gear
  127
• 4.1 Assembly overview - valve gear
  127
• 4.2 Measuring axial play of camshaft
  129
• 4.3 Removing and installing valve stem seals
  130
• 5 Inlet and exhaust valves
  132
• 5.1 Reworking valve seats
  132
• 5.2 Checking valve guides
  133
• Lubrication
  134
• 1 Sump, oil pump
  134
• 1.1 Assembly overview - sump/oil pump
  134
• 1.2 Removing and installing oil sump
  137
• 1.3 Removing and installing oil pump
  139
• 1.4 Engine oil:
  142
• 2 Oil filter, oil pressure switch
  143
• 2.1 Checking oil pressure and oil pressure switch
  143
• Cooling
  145
• 1 Cooling system/coolant
  145
• 1.1 Connection diagram - coolant hoses
  145
• 1.2 Checking cooling system for leaks
  145
• 1.3 Draining and adding coolant
  147
• 2 Coolant pump, regulation of cooling system
  154
• 2.1 Assembly overview - thermostat
  154
• 2.2 Removing and installing coolant pump
  155
• 2.3 Removing and installing coolant pump pulley
  159
• 2.4 Removing and installing electric coolant pump
  162
• 3 Radiator, radiator fan
  165
• 3.1 Assembly overview - radiator/radiator fan
  165
• 3.2 Removing and installing radiator
  166
• 3.3 Removing and installing radiator cowl with radiator fan
  167
• 3.4 Removing and installing radiator fan
  168
• Turbocharging/supercharging
  169
• 1 Exhaust turbocharger
  169
• 1.1 Assembly overview - turbocharger
  169
• 1.2 Removing and installing turbocharger
  172
• 1.3 Checking vacuum unit for turbocharger
  177
• 1.4 Adjusting vacuum unit for turbocharger
  178
• 1.5 Renewing vacuum unit for turbocharger
  184
• 2 Charge air system
  187
• 2.1 Assembly overview - charge air system
  187
• 2.2 Removing and installing charge air cooler
  190
• 2.3 Assembly overview - charge-air hose connections
  192
• 2.4 Checking charge air system for leaks
  193
• 3 Compressor
  196
• 3.1 Assembly overview - supercharger
  196
• 3.2 Removing and installing supercharger
  198
• 3.3 Removing and installing ancillary drive unit and decoupling spring
  203
• Mixture preparation - injection
  207
• 1 Injectors
  207
• 1.1 Assembly overview - fuel rail with injectors
  207
• 1.2 Removing and installing injectors
  207
• 1.3 Renewing seals on injectors
  210
• 1.4 Cleaning injectors
  213
• 2 High-pressure pump
  215
• 2.1 Assembly overview - high-pressure pump
  215
• 2.2 Removing and installing high-pressure pump
  216
• 3 Senders and sensors
  219
• 3.2 Checking fuel pressure sender G247
  221
• 4 Intake manifold
  226
• 4.1 Assembly overview - intake manifold
  226
• 4.2 Assembly overview - lower part of intake manifold with fuel rail
  229
• 4.3 Removing and installing lower part of intake manifold
  230
• 4.4 Removing and installing throttle valve module J338
  230
• 4.5 Cleaning throttle valve module
  231
• 4.6 Removing and installing regulating flap control unit J808
  232
• 5 Air filter
  234
• 5.1 Assembly overview - air filter housing
  234
• 5.2 Removing and installing air filter housing
  235
• 6 Engine (motor) control unit
  236
• 6.1 Removing and installing engine (motor) control unit J623
  236
• Exhaust system
  238
• 1 Exhaust pipes, silencers
  238
• 1.1 Assembly overview - silencers
  238
• 1.2 Removing and installing front exhaust pipe
  239
• 1.3 Separating exhaust pipes, silencers
  240
• 1.4 Aligning exhaust system free of stress
  241
• 1.5 Installation position of clamp
  243
• 2 Exhaust gas cleaning
  244
• 2.1 Assembly overview - emission control
  244
• 2.2 Removing and installing catalytic converter
  245
• Ignition system
  248
• 1 Ignition system
  248
• 1.1 Assembly overview - ignition system
  248
• 1.2 Test data, spark plugs
  249
• 1.3 Removing and installing ignition coils with output stage
  249
• 1.4 Removing and installing engine speed sender G28
  251