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 cooling system
  4
• 2.3 Safety precautions when working on ignition system
  5
• 3 Repair instructions
  6
• 3.1 Rules for cleanliness
  6
• Removing and installing engine
  7
• 1 Removing and installing engine
  7
• 1.1 Removing engine
  7
• 1.2 Securing engine on engine and gearbox support
  15
• 1.3 Installing engine
  15
• 2 Assembly mountings
  19
• 2.1 Assembly overview - assembly mountings
  19
• Crankshaft group
  20
• 1 Cylinder block (pulley end)
  20
• 1.1 Assembly overview - poly V-belt drive
  20
• 1.2 Assembly overview - cylinder block (pulley end)
  21
• 1.3 Removing and installing poly V-belt
  23
• 1.4 Removing and installing ancillary bracket
  24
• 1.5 Removing and installing belt pulley
  25
• 1.6 Renewing crankshaft oil seal - belt pulley end
  29
• 2 Cylinder block, gearbox end
  32
• 2.1 Assembly overview - cylinder block, gearbox end
  32
• 2.2 Renewing crankshaft oil seal - gearbox end
  33
• 3 Crankshaft
  42
• 3.1 Assembly overview - crankshaft
  42
• 3.2 Crankshaft dimensions
  43
• 3.3 Renewing needle bearing in crankshaft
  43
• 4 Pistons and conrods
  45
• 4.1 Assembly overview - pistons and conrods
  45
• 4.2 Removing and installing pistons
  46
• 4.3 Removing and installing oil spray jets
  47
• 4.4 Checking piston and cylinder bore
  49
• 4.5 Separating new conrod
  50
• Cylinder head, valve gear
  51
• 1 Cylinder head
  51
• 1.1 Assembly overview - cylinder head
  51
• 1.2 Removing and installing camshaft housing
  54
• 1.3 Removing and installing cylinder head
  59
• 1.4 Checking compression
  62
• 2 Cover for timing chain
  65
• 2.1 Removing and installing valve timing housing
  65
• 3 Chain drive
  69
• 3.1 Removing and installing timing chain and chain drive for oil pump
  69
• 3.2 Checking valve timing
  77
• 3.3 Adjusting valve timing
  80
• 3.4 Checking timing chain
  89
• 4 Valve gear
  95
• 4.1 Assembly overview - valve gear
  95
• 4.2 Measuring axial clearance of camshaft
  97
• 4.3 Removing and installing camshaft
  97
• 4.4 Removing and installing valve stem seals
  98
• 5 Inlet and exhaust valves
  100
• 5.1 Reworking valve seats
  100
• 5.2 Checking valve guides
  101
• 5.3 Valve dimensions
  102
• Lubrication
  103
• 1 Sump, oil pump
  103
• 1.1 Assembly overview - sump / oil pump
  103
• 1.2 Engine oil
  106
• 1.3 Removing and installing oil sump
  106
• 1.4 Removing and installing oil pump
  108
• 2 Oil filter, oil pressure switch
  111
• 2.1 Checking oil pressure and oil pressure switch
  111
• Cooling
  113
• 1 Cooling system, coolant
  113
• 1.1 Coolant hose schematic diagram
  113
• 1.2 Checking cooling system for leaks
  114
• 1.3 Draining and filling coolant
  116
• 2 Coolant pump, regulation of cooling system
  120
• 2.1 Assembly overview - thermostat
  120
• 2.2 Removing and installing coolant pump
  121
• 2.3 Removing and installing electric coolant pump
  122
• 3 Coolers, radiator, radiator fan
  125
• 3.1 Assembly overview - radiator/radiator fan
  125
• 3.2 Removing and installing radiator
  127
• 3.3 Removing and installing radiator fan
  128
• Turbocharging/supercharging
  130
• 1 Turbocharger
  130
• 1.1 Assembly overview - turbocharger
  130
• 1.2 Removing and installing turbocharger
  134
• 1.3 Removing and installing compressor housing and turbine housing
  139
• 1.4 Checking vacuum unit for turbocharger
  143
• 1.5 Adjusting vacuum unit for turbocharger
  145
• 1.6 Renewing vacuum unit for turbocharger
  151
• 2 Charge air system
  154
• 2.1 Assembly overview - charge air system
  154
• 2.2 Removing and installing charge air cooler
  155
• Mixture preparation - injection
  157
• 1 Injection system
  157
• 1.1 Assembly overview - fuel system
  157
• 2 Injectors
  159
• 2.1 Assembly overview - fuel rail with injectors
  159
• 2.2 Removing and installing injectors
  160
• 2.3 Renewing seals on injectors
  163
• 3 Air filter
  168
• 3.1 Assembly overview - air filter housing
  168
• 3.2 Removing and installing air filter housing
  169
• 4 Intake manifold
  170
• 4.1 Assembly overview - intake manifold
  170
• 4.2 Removing and installing intake manifold
  171
• 4.3 Removing and installing throttle valve module
  172
• 4.4 Cleaning throttle valve module
  175
• 5 Senders and sensors
  177
• 5.1 Checking fuel pressure sender
  177
• 6 Engine control unit
  180
• 6.1 Removing and installing engine control unit
  180
• 6.2 Removing and installing engine control unit with protective housing
  181
• 7 High-pressure pump
  184
• 7.1 Assembly overview - high-pressure pump
  184
• 7.2 Removing and installing high-pressure pump
  185
• Exhaust system
  189
• 1 Exhaust pipes, silencers
  189
• 1.1 Assembly overview - silencers
  189
• 1.2 Separating exhaust pipes, silencers
  190
• 1.3 Installation position of clamp
  191
• 2 Cleansing exhaust emissions
  193
• 2.1 Assembly overview - emission control
  193
• Ignition system
  195
• 1 Ignition system
  195
• 1.1 Assembly overview - ignition system
  195
• 1.2 Test data, spark plugs
  196
• 1.3 Removing and installing ignition coils with output stage
  197
• 1.4 Removing and installing engine speed sender
  198