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
  2
• 1 Removing and installing engine
  2
• 1.1 Removing engine
  3
• 1.2 Securing engine to assembly stand
  9
• 1.3 Installing engine
  9
• 1.4 Torque settings
  11
• 1.5 Assembly mountings
  12
• 1.6 Additional notes and assembly work for vehicles with air conditioner
  13
• Crankshaft group
  14
• 1 Dismantling and assembling engine
  14
• 1.1 Parts I and II - assembly overview
  15
• 1.2 Part I Assembly overview - belt drive
  16
• 1.3 Part II Assembly overview - cylinder block
  17
• 1.4 Removing and installing poly V-belt
  19
• 1.5 Removing and installing valve timing housing
  22
• 2 Removing and installing sealing flanges and flywheel or drive plate
  25
• 2.1 Assembly overview
  25
• 2.2 Renewing crankshaft oil seal - belt pulley end
  27
• 2.3 Removing and installing crankshaft pulley
  29
• 2.4 Renewing crankshaft sealing flange - flywheel end
  31
• 3 Crankshaft
  39
• 3.1 Assembly overview - crankshaft
  39
• 3.2 Crankshaft dimensions
  40
• 4 Dismantling and assembling pistons and conrods
  41
• 4.1 Assembly overview
  41
• 4.2 Checking piston
  42
• 4.3 Piston and cylinder dimensions
  43
• Cylinder head, valve gear
  44
• 1 Cylinder head
  44
• 1.1 Assembly overview
  45
• 1.2 Checking valve timing
  47
• 1.3 Adjusting valve timing
  49
• 1.4 Removing and installing camshaft housing
  55
• 1.5 Removing and installing cylinder head
  58
• 1.6 Checking compression
  61
• 2 Valve gear
  63
• 2.1 Assembly overview
  63
• 2.2 Checking camshaft axial clearance
  64
• 2.3 Reworking valve seats
  65
• 2.4 Checking valve guides
  66
• 2.5 Renewing valve stem seals
  67
• Lubrication
  69
• 1 Parts of lubrication system
  69
• 1.1 Engine oil
  69
• 1.2 Assembly overview
  70
• 1.3 Removing and installing sump
  72
• 1.4 Removing and installing oil pump
  73
• 1.5 Checking oil pressure and oil pressure switch
  76
• Cooling
  78
• 1 Parts of cooling system
  78
• 1.1 Assembly overview - parts of cooling system, body side
  79
• 1.2 Assembly overview - parts of cooling system, engine side
  80
• 1.3 Coolant hose schematic diagram
  81
• 1.4 Draining and filling coolant
  82
• 1.5 Removing and installing radiator fan V7 and radiator fan 2 V177
  84
• 1.6 Removing and installing radiator
  86
• 1.7 Removing and installing coolant pump
  87
• 1.8 Removing and installing coolant circulation pump V50
  91
• Fuel supply system
  93
• 1 Safety precautions
  93
• 1.1 Safety precautions when working on fuel supply system
  93
• 1.2 Releasing pressure in high-pressure section
  93
• 2 Fuel tank
  95
• 2.1 Safety precautions when working on fuel supply system
  95
• 2.2 Releasing pressure in high-pressure section
  95
• 2.3 Rules for cleanliness
  96
• 2.4 Assembly overview - fuel tank
  97
• 2.5 Emptying fuel tank
  98
• 2.6 Removing and installing fuel tank
  101
• 3 Removing and installing parts of fuel supply system
  103
• 3.1 Safety precautions when working on fuel supply system
  103
• 3.2 Releasing pressure in high-pressure section
  104
• 3.3 Rules for cleanliness
  104
• 3.4 Removing and installing fuel delivery unit
  105
• 3.5 Removing and installing fuel gauge sender G
  107
• 3.6 Crash fuel shut-off
  107
• 3.7 Checking fuel pump
  108
• 3.8 Assembly overview - high-pressure pump
  114
• 3.9 Removing and installing high-pressure pump
  114
• 4 Repairing electronic power control (EPC)
  119
• 4.1 Function of EPC system
  119
• 4.2 Assembly overview
  120
• 4.3 Removing and installing accelerator pedal module
  120
• 5 Activated charcoal filter system
  122
• 5.1 Function
  122
• 5.2 Checking fuel tank breather
  122
• Turbocharging/supercharging
  124
• 1 Turbocharger
  124
• 1.1 Assembly overview - turbocharger
  124
• 1.2 Part I
  125
• 1.3 Part II
  126
• 1.4 Removing and installing turbocharger
  126
• 1.5 Checking turbocharger vacuum unit
  130
• 2 Compressor
  133
• 2.1 Assembly overview - compressor
  133
• 2.2 Removing and installing compressor
  134
• 3 Charge air system
  141
• 3.1 Assembly overview - charge air system
  141
• 3.2 Checking charge air system for leaks
  141
• Mixture preparation - injection
  145
• 1 Repairing injection system
  145
• 1.1 Parts l and II - assembly overview - intake manifold
  145
• 1.2 Part I - assembly overview - intake manifold
  147
• 1.3 Part II - assembly overview - intake manifold
  149
• 1.4 Assembly overview - fuel rail with injectors
  151
• 1.5 Checking vacuum reservoir for leaks
  152
• 1.6 Assembly overview - air filter
  153
• 1.7 Removing and installing air filter
  153
• 1.8 Removing and installing regulating flap control unit J808 and throttle valve module J338
  154
• 1.9 Cleaning throttle valve module J338
  157
• 1.10 Removing and installing injectors
  158
• 1.11 Safety precautions
  161
• 1.12 Rules for cleanliness
  163
• 1.13 Technical data
  163
• 2 Engine control unit
  164
• 2.1 Removing and installing engine control unit
  164
• 2.2 Removing and installing anti-theft engine control unit
  165
• Exhaust system
  168
• 1 Parts of exhaust system
  168
• 1.1 Assembly overview - catalytic converter and attachments
  168
• 1.2 Assembly overview - silencers with mountings
  170
• 1.3 Separating centre and rear silencers
  170
• Ignition system
  173
• 1 Repairing ignition system
  173
• 1.1 Assembly overview - ignition system
  173
• 1.2 Removing and installing ignition coils with output stage
  174
• 1.3 Safety precautions
  175
• 1.4 Spark plug test data
  176