4-cylinder injection engine (1.4 l direct injection engine, turbocharger)

Chapter overview

• Technical data
  1
• 1 Identification
  1
• 1.1 Engine number, engine data
  1
• 2 Safety instructions
  3
• 2.1 Safety precautions when working on fuel supply system
  3
• 2.2 Safety precautions when working on vehicles with a Start/Stop system
  3
• 2.4 Safety precautions when working on cooling system
  4
• 2.5 Safety precautions when working on ignition system
  4
• 3 Repair instructions
  5
• 3.1 Rules for cleanliness
  5
• Removing and installing engine
  6
• 1 Removing and installing engine
  6
• 1.1 Removing engine
  6
• 1.2 Securing engine on engine and gearbox support
  14
• 1.3 Installing engine
  14
• 2 Assembly mountings
  17
• 2.1 Assembly overview - assembly mountings
  17
• Crankshaft group
  18
• 1 Cylinder block (pulley end)
  18
• 1.1 Assembly overview - poly V-belt drive
  18
• 1.2 Assembly overview - cylinder block (pulley end)
  19
• 1.3 Removing and installing poly V-belt
  21
• 1.4 Removing and installing ancillary bracket
  22
• 1.5 Removing and installing belt pulley
  23
• 1.6 Renewing crankshaft oil seal - belt pulley end
  27
• 2 Cylinder block, gearbox end
  30
• 2.1 Assembly overview - cylinder block, gearbox end
  30
• 2.2 Renewing crankshaft oil seal - gearbox end
  31
• 3 Crankshaft
  39
• 3.1 Assembly overview - crankshaft
  39
• 3.2 Crankshaft dimensions
  40
• 3.3 Renewing needle bearing in crankshaft
  40
• 4 Pistons and conrods
  42
• 4.1 Assembly overview - pistons and conrods
  42
• 4.2 Removing and installing pistons
  43
• 4.3 Removing and installing oil spray jets
  44
• 4.4 Checking piston and cylinder bore
  46
• 4.5 Separating new conrod
  47
• Cylinder head, valve gear
  48
• 1 Cylinder head
  48
• 1.1 Assembly overview - cylinder head
  48
• 1.2 Removing and installing camshaft housing
  51
• 1.3 Removing and installing cylinder head
  56
• 1.4 Checking compression
  59
• 2 Cover for timing chain
  62
• 2.1 Removing and installing valve timing housing
  62
• 3 Chain drive
  66
• 3.1 Removing and installing timing chain and chain drive for oil pump
  66
• 3.2 Checking valve timing
  74
• 3.3 Adjusting valve timing
  77
• 3.4 Checking timing chain
  86
• 4 Valve gear
  92
• 4.1 Assembly overview - valve gear
  92
• 4.2 Measuring axial play of camshaft
  94
• 4.3 Removing and installing camshaft
  94
• 4.4 Removing and installing valve stem seals
  95
• 5 Inlet and exhaust valves
  97
• 5.1 Reworking valve seats
  97
• 5.2 Checking valve guides
  98
• 5.3 Valve dimensions
  99
• Lubrication
  100
• 1 Sump, oil pump
  100
• 1.1 Assembly overview - sump / oil pump
  100
• 1.2 Engine oil
  103
• 1.3 Removing and installing oil sump
  103
• 1.4 Removing and installing oil pump
  105
• 2 Oil filter, oil pressure switch
  108
• 2.1 Checking oil pressure and oil pressure switch
  108
• Cooling
  110
• 1 Cooling system, coolant
  110
• 1.1 Coolant hose schematic diagram
  110
• 1.2 Checking cooling system for leaks
  111
• 1.3 Draining and filling coolant
  113
• 2 Coolant pump, regulation of cooling system
  117
• 2.1 Assembly overview - thermostat
  117
• 2.2 Removing and installing coolant pump
  118
• 2.3 Removing and installing electric coolant pump
  119
• 3 Radiator, radiator fan
  122
• 3.1 Assembly overview - radiator/radiator fan
  122
• 3.2 Removing and installing radiator
  124
• 3.3 Removing and installing radiator fan V7 and radiator fan 2 V177
  125
• Turbocharging/supercharging
  127
• 1 Turbocharger
  127
• 1.1 Assembly overview - turbocharger
  127
• 1.2 Removing and installing turbocharger
  131
• 1.3 Removing and installing compressor housing and turbine housing
  136
• 1.4 Checking vacuum unit for turbocharger
  140
• 1.5 Adjusting vacuum unit for turbocharger
  142
• 1.6 Renewing vacuum unit for turbocharger
  148
• 2 Charge air system
  151
• 2.1 Assembly overview - charge air system
  151
• 2.2 Removing and installing charge air cooler
  152
• Mixture preparation - injection
  154
• 1 Injection system
  154
• 1.1 Assembly overview - fuel system
  154
• 1.2 Releasing high pressure in fuel system
  155
• 2 Injectors
  156
• 2.1 Assembly overview - fuel rail with injectors
  156
• 2.2 Removing and installing injectors
  157
• 2.3 Renewing seals on injectors
  160
• 3 Air filter
  165
• 3.1 Assembly overview - air filter housing
  165
• 3.2 Removing and installing air filter housing
  166
• 4 Intake manifold
  167
• 4.1 Assembly overview - intake manifold
  167
• 4.2 Removing and installing intake manifold
  168
• 4.3 Removing and installing throttle valve module J338
  169
• 4.4 Cleaning throttle valve module
  172
• 5 Senders and sensors
  174
• 5.1 Checking fuel pressure sender G247
  174
• 6 Engine control unit
  177
• 6.1 Removing and installing engine control unit J623
  177
• 6.2 Removing and installing engine control unit J623 with protective housing
  178
• 7 High-pressure pump
  181
• 7.1 Assembly overview - high-pressure pump
  181
• 7.2 Removing and installing high-pressure pump
  182
• Exhaust system
  186
• 1 Exhaust pipes, silencers
  186
• 1.1 Assembly overview - silencers
  186
• 1.2 Separating exhaust pipes, silencers
  187
• 1.3 Installation position of clamp
  188
• 2 Emission control
  190
• 2.1 Assembly overview - emission control
  190
• Ignition system
  192
• 1 Ignition system
  192
• 1.1 Assembly overview - ignition system
  192
• 1.2 Test data, spark plugs
  193
• 1.3 Removing and installing ignition coils with output stage
  194
• 1.4 Removing and installing engine speed sender G28
  195