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

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Engine number
  1
• 1.2 Engine data
  1
• Removing and installing engine
  3
• 1 Removing and installing engine
  3
• 1.1 Removing engine
  3
• 1.2 Securing engine to assembly stand
  11
• 1.3 Installing engine
  11
• 1.4 Specified torques
  14
• 1.5 Additional information and assembly work for vehicles with air conditioner
  14
• 2 Assembly mountings
  15
• 2.1 Assembly mountings
  15
• Crankshaft group
  16
• 1 Dismantling and assembling engine
  16
• 1.1 Assembly overview - parts l and ll
  16
• 1.2 Assembly overview - part I, belt drive
  18
• 1.3 Assembly overview - part II, cylinder block
  19
• 1.4 Removing and installing poly V-belt
  21
• 1.5 Removing and installing valve timing housing
  22
• 1.6 Removing and installing ancillary bracket
  26
• 2 Sealing flanges and flywheel
  28
• 2.1 Assembly overview
  28
• 2.2 Removing and installing engine speed sender G28
  29
• 2.3 Renewing crankshaft oil seal - belt pulley end
  30
• 2.4 Removing and installing crankshaft pulley
  31
• 2.5 Renewing crankshaft sealing flange - flywheel end
  34
• 3 Crankshaft
  43
• 3.1 Assembly overview
  43
• 3.2 Pulling needle bearing out of and driving into crankshaft
  44
• 3.3 Crankshaft dimensions
  45
• 4 Pistons and conrods
  46
• 4.1 Assembly overview
  46
• 4.2 Checking piston
  47
• 4.3 Separating new conrod
  48
• 4.4 Piston and cylinder dimensions
  49
• Cylinder head, valve gear
  50
• 1 Cylinder head
  50
• 1.1 Assembly overview
  50
• 1.2 Checking valve timing
  53
• 1.3 Adjusting valve timing
  56
• 1.4 Checking timing chain
  64
• 1.5 Removing and installing timing chain and drive chain for oil pump
  69
• 1.6 Removing and installing camshaft housing
  77
• 1.7 Removing and installing cylinder head
  83
• 1.8 Checking compression
  86
• 2 Valve gear
  89
• 2.1 Assembly overview
  89
• 2.2 Checking camshaft axial clearance
  91
• 2.3 Reworking valve seats
  91
• 2.4 Checking valve guides
  93
• 2.5 Renewing valve stem seals
  93
• Lubrication
  96
• 1 Parts of lubrication system
  96
• 1.1 Engine oil, oil capacities, engine oil specification
  96
• 1.2 Assembly overview - ► model year 2008
  96
• 1.3 Assembly overview - model year 2009 ►
  99
• 1.4 Removing and installing oil sump
  101
• 1.5 Removing and installing oil pump
  103
• 1.6 Checking oil pressure and oil pressure switch
  105
• Cooling
  108
• 1 Parts of cooling system
  108
• 1.1 Assembly overview - parts of cooling system, body side
  109
• 1.2 Assembly overview - parts of cooling system, engine side
  110
• 1.3 Coolant hose schematic diagram
  111
• 1.4 Draining, filling and bleeding cooling system
  113
• 1.5 Removing and installing radiator fan V7 and radiator fan 2 V177
  116
• 1.6 Checking cooling system for leaks
  117
• 1.7 Removing and installing radiator
  118
• 1.8 Removing and installing coolant pump
  120
• 1.9 Removing and installing coolant circulation pump V50
  121
• Fuel supply system
  124
• 1 Safety precautions
  124
• 1.1 Safety precautions when working on fuel supply system
  124
• 1.2 Releasing pressure in high-pressure area
  125
• 2 Fuel tank
  127
• 2.1 Assembly overview - fuel tank
  127
• 2.2 Emptying fuel tank
  129
• 2.3 Removing and installing fuel tank
  131
• 3 Repairing fuel supply system
  134
• 3.1 Rules for cleanliness
  134
• 3.2 Removing and installing fuel delivery unit
  134
• 3.3 Removing and installing fuel gauge sender G
  136
• 3.4 Crash fuel shut-off
  137
• 3.5 Checking fuel pump
  137
• 4 Electronic power control (EPC)
  148
• 4.1 Function of EPC system
  148
• 4.2 Assembly overview - accelerator module
  148
• 4.3 Removing and installing accelerator module
  149
• 5 Activated charcoal filter system
  152
• 5.1 Function
  152
• 5.2 Assembly overview - activated charcoal filter system
  152
• 5.3 Checking fuel tank breather
  153
• Turbocharging/supercharging
  155
• 1 Turbocharger
  155
• 1.1 General repair instructions
  155
• 1.2 Safety precautions
  156
• 1.3 Rules for cleanliness
  156
• 1.4 Assembly overview - turbocharger
  157
• 1.5 Assembly overview - part I, turbocharger
  158
• 1.6 Assembly overview - part II, turbocharger
  159
• 1.7 Removing and installing turbocharger
  160
• 1.8 Removing and installing compressor housing and turbine housing
  165
• 1.9 Checking vacuum unit for turbocharger
  169
• 1.10 Removing and installing vacuum unit for turbocharger
  171
• 1.11 Adjusting vacuum unit for turbocharger
  174
• 2 Charge air system
  181
• 2.1 Assembly overview - charge air system
  181
• 2.2 Removing and installing radiator for charge air cooler
  182
• Mixture preparation - injection
  184
• 1 Injection system
  184
• 1.1 General notes on injection
  184
• 1.2 Safety precautions
  185
• 1.3 Rules for cleanliness
  186
• 1.4 Technical data
  186
• 1.5 Assembly overview - parts l and II, intake manifold
  186
• 1.6 Assembly overview - part I, intake manifold
  188
• 1.7 Assembly overview - part II, intake manifold
  189
• 1.8 Assembly overview - intake manifold lower part/fuel rail with injectors
  190
• 1.9 Assembly overview - air filter
  191
• 1.10 Removing and installing air filter
  192
• 1.11 Removing and installing throttle valve module J338
  192
• 1.12 Cleaning throttle valve module J338
  195
• 1.13 Removing and installing intake manifold
  196
• 1.14 Assembly overview - high-pressure pump
  197
• 1.15 Checking fuel pressure in high-pressure section
  198
• 1.16 Removing and installing high-pressure pump
  201
• 1.17 Removing and installing injectors
  205
• 1.18 Renewing Teflon seal and support washer on injector
  207
• 2 Engine control unit J623
  211
• 2.1 Reading and erasing engine control unit fault memory
  211
• 2.2 Removing and installing engine control unit
  212
• Exhaust system
  216
• 1 Parts of exhaust system
  216
• 1.1 Assembly overview - catalytic converter and attachments
  218
• 1.2 Assembly overview - silencers with mountings
  220
• 1.3 Separating and joining front and rear silencers
  221
• 1.4 Aligning exhaust system free of stress
  222
• 1.5 Installation position and specified torque of clamp
  224
• Ignition system
  226
• 1 Ignition system
  226
• 1.1 Assembly overview - ignition system
  226
• 1.2 Removing and installing ignition coils with output stage
  227
• 1.3 Safety precautions
  228
• 1.4 Test data, spark plugs
  229