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
  2
• 2.1 Safety precautions when working on fuel supply system
  2
• 2.2 Safety precautions when working on vehicles with a Start/Stop system
  2
• 2.4 Safety precautions when working on cooling system
  3
• 2.5 Safety precautions when working on ignition system
  3
• 3 Repair instructions
  4
• 3.1 Rules for cleanliness
  4
• 3.2 Foreign objects in engine
  4
• 3.3 Contact corrosion
  4
• 3.4 Routing and securing lines
  4
• 3.5 Installing coolers, condensers and radiators
  5
• Removing and installing engine
  6
• 1 Removing and installing engine
  6
• 1.1 Removing engine
  6
• 1.2 Separating engine and gearbox
  16
• 1.3 Securing engine on engine and gearbox support
  18
• 1.4 Installing engine
  19
• 2 Assembly mountings
  23
• 2.1 Assembly overview - assembly mountings
  23
• 2.2 Supporting engine in installation position
  25
• 2.3 Removing and installing engine mountings
  27
• 2.4 Removing and installing gearbox mounting
  28
• 2.5 Removing and installing pendulum support
  30
• 2.6 Checking adjustment of assembly mountings (engine and gearbox mountings)
  30
• 2.7 Adjusting assembly mountings
  30
• Crankshaft group
  33
• 1 Cylinder block (pulley end)
  33
• 1.1 Assembly overview - poly V-belt drive
  33
• 1.2 Assembly overview - sealing flange, belt pulley end
  37
• 1.3 Removing and installing poly V-belt
  38
• 1.4 Removing and installing tensioner for poly V-belt
  42
• 1.5 Removing and installing vibration damper
  42
• 1.6 Removing and installing engine support
  43
• 1.7 Renewing crankshaft oil seal - belt pulley end
  46
• 1.8 Removing and installing sealing flange on pulley end
  48
• 2 Cylinder block, gearbox end
  51
• 2.1 Assembly overview - cylinder block, gearbox end
  51
• 2.2 Removing and installing flywheel
  52
• 2.3 Removing and installing sealing flange on gearbox side
  53
• 3 Crankshaft
  63
• 3.1 Renewing needle bearing in crankshaft
  63
• 3.2 Crankshaft dimensions
  64
• 3.3 Measuring axial clearance of crankshaft
  64
• 4 Pistons and conrods
  66
• 4.1 Assembly overview - pistons and conrods
  66
• 4.2 Removing and installing pistons
  68
• 4.3 Removing and installing oil spray jets
  69
• 4.4 Checking pistons and cylinder bores
  70
• 4.5 Checking radial clearance of conrods
  71
• Cylinder head, valve gear
  73
• 1 Toothed belt drive
  73
• 1.1 Assembly overview - toothed belt cover
  73
• 1.2 Assembly overview - toothed belt
  74
• 1.3 Checking valve timing
  75
• 1.4 Removing toothed belt from camshaft
  80
• 1.5 Removing and installing toothed belt
  91
• 2 Cylinder head
  104
• 2.1 Assembly overview - cylinder head
  104
• 2.2 Assembly overview - camshaft housing
  106
• 2.3 Removing and installing cylinder head
  107
• 2.4 Removing and installing camshaft housing
  111
• 2.5 Checking compression
  115
• 3 Valve gear
  118
• 3.1 Assembly overview - valve gear
  118
• 3.2 Removing and installing inlet camshaft control valve 1 N205
  119
• 3.3 Removing and installing camshaft adjuster
  119
• 3.4 Measuring axial play of camshaft
  120
• 3.5 Removing and installing camshaft oil seal
  121
• 3.6 Removing and installing valve stem seal
  126
• 4 Inlet and exhaust valves
  134
• 4.1 Checking valve guides
  134
• 4.2 Checking valves
  134
• 4.3 Valve dimensions
  135
• Lubrication
  136
• 1 Sump, oil pump
  136
• 1.1 Assembly overview - sump and oil pump
  136
• 1.2 Removing and installing oil level and oil temperature sender G266
  139
• 1.3 Removing and installing lower part of sump
  139
• 1.4 Removing and installing oil pump
  142
• 1.5 Removing and installing upper part of sump
  143
• 1.6 Engine oil
  146
• 2 Engine oil cooler
  147
• 2.1 Assembly overview - engine oil cooler
  147
• 2.2 Removing and installing engine oil cooler
  147
• 3 Crankcase breather
  149
• 3.1 Assembly overview - crankcase breather system
  149
• 3.2 Removing and installing oil separator
  150
• 4 Oil filter, oil pressure switch
  153
• 4.1 Assembly overview - oil filter/oil pressure switch
  153
• 4.2 Removing and installing oil pressure switch F1
  154
• 4.3 Removing and installing oil pressure switch for reduced oil pressure F378
  155
• 4.4 Removing and installing oil pressure regulating valve N428
  156
• 4.5 Checking oil pressure
  157
• Cooling
  160
• 1 Cooling system, coolant
  160
• 1.1 Coolant hose schematic diagram
  160
• 1.2 Draining and filling coolant
  161
• 1.3 Checking cooling system for leaks
  166
• 2 Coolant pump, regulation of cooling system
  168
• 2.1 Assembly overview - coolant pump, thermostat
  168
• 2.2 Assembly overview - electric coolant pump
  170
• 2.3 Assembly overview - coolant temperature sender
  172
• 2.4 Removing and installing coolant pump
  173
• 2.5 Removing and installing toothed belt pulley for coolant pump
  176
• 2.6 Removing and installing thermostat
  177
• 2.7 Removing and installing electric coolant pump
  180
• 2.8 Removing and installing coolant temperature sender G62
  182
• 3 Coolant pipes
  185
• 3.1 Assembly overview - coolant pipes
  185
• 3.2 Removing and installing coolant pipes
  185
• 4 Radiator and radiator fan
  189
• 4.1 Assembly overview - radiator and radiator fan
  189
• 4.2 Assembly overview - radiator cowl and radiator fan
  191
• 4.3 Removing and installing radiator
  192
• 4.4 Removing and installing radiator cowling
  193
• 4.5 Removing and installing radiator fan V7 and radiator fan 2 V177
  194
• Turbocharging/supercharging
  196
• 1 Turbocharger
  196
• 1.1 Assembly overview - turbocharger
  196
• 1.2 Removing and installing turbocharger
  198
• 1.3 Removing and installing charge pressure positioner V465
  202
• 2 Charge air system
  206
• 2.1 Assembly overview - charge air system
  206
• 2.2 Removing and installing charge pressure sender GX26
  208
• 2.3 Removing and installing charge air cooler
  208
• 2.4 Checking charge air system for leaks
  211
• Mixture preparation - injection
  214
• 1 Injection system
  214
• 1.1 Overview of fitting locations - injection system
  214
• 1.2 Releasing high pressure in fuel system
  217
• 2 Air filter
  219
• 2.1 Assembly overview - air filter housing
  219
• 2.2 Removing and installing air filter housing
  220
• 3 Intake manifold
  221
• 3.1 Assembly overview - intake manifold
  221
• 3.2 Removing and installing intake manifold
  222
• 3.3 Removing and installing throttle valve module GX3
  225
• 3.4 Cleaning throttle valve module GX3
  226
• 4 Injectors
  228
• 4.1 Assembly overview - fuel rail with injectors
  228
• 4.2 Removing and installing fuel rail
  229
• 4.3 Removing and installing injectors
  230
• 4.4 Cleaning injectors
  234
• 5 Senders and sensors
  236
• 5.1 Removing and installing intake manifold sender GX9
  236
• 5.2 Removing and installing fuel pressure sender G247
  236
• 5.3 Checking fuel pressure sender G247
  237
• 6 High-pressure pump
  240
• 6.1 Assembly overview - high-pressure pump
  240
• 6.2 Removing and installing high-pressure pump
  241
• 6.3 Removing and installing high-pressure pipe
  242
• 7 Lambda probe
  244
• 7.1 Assembly overview - Lambda probe
  244
• 8 Engine control unit
  247
• 8.1 Removing and installing engine control unit J623
  247
• Exhaust system
  251
• 1 Exhaust pipes, silencers
  251
• 1.1 Assembly overview - silencers
  251
• 1.2 Removing and installing silencer
  252
• 1.3 Separating exhaust pipes, silencers
  253
• 1.4 Aligning exhaust system free of tension
  253
• 1.5 Checking exhaust system for leaks
  254
• 2 Emission control
  255
• 2.1 Assembly overview - emission control
  255
• 2.2 Removing and installing catalytic converter
  256
• Ignition system
  260
• 1 Ignition system
  260
• 1.1 Assembly overview - ignition system
  260
• 1.2 Test data, spark plugs
  261
• 1.3 Removing and installing ignition coils with output stage
  261
• 1.4 Removing and installing knock sensor 1 G61
  263
• 1.5 Removing and installing Hall sender G40
  264
• 1.6 Removing and installing engine speed sender G28
  264