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
  15
• 1.3 Securing engine on engine and gearbox support
  17
• 1.4 Installing engine
  18
• 2 Assembly mountings
  21
• 2.1 Assembly overview - assembly mountings
  21
• 2.2 Supporting engine in installation position
  26
• 2.3 Removing and installing engine mountings
  29
• 2.4 Removing and installing gearbox mounting
  31
• 2.5 Removing and installing pendulum support
  32
• Crankshaft group
  35
• 1 Cylinder block (pulley end)
  35
• 1.1 Assembly overview - poly V-belt drive
  35
• 1.2 Assembly overview - Sealing flange, belt pulley end
  38
• 1.3 Removing and installing poly V-belt
  39
• 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
  47
• 1.8 Removing and installing sealing flange on pulley end
  49
• 2 Cylinder block, gearbox end
  52
• 2.1 Assembly overview - cylinder block, gearbox end
  52
• 2.2 Removing and installing flywheel
  53
• 2.3 Removing and installing sealing flange on gearbox side
  54
• 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 Separating new conrod
  68
• 4.3 Removing and installing pistons
  68
• 4.4 Removing and installing oil spray jets
  69
• 4.5 Checking piston and cylinder bore
  70
• 4.6 Checking radial clearance of conrods
  71
• Cylinder head, valve gear
  72
• 1 Toothed belt drive
  72
• 1.1 Assembly overview - toothed belt cover
  72
• 1.2 Assembly overview - toothed belt
  73
• 1.3 Checking valve timing
  74
• 1.4 Detaching toothed belt from camshaft
  80
• 1.5 Removing and installing toothed belt
  94
• 2 Cylinder head
  109
• 2.1 Assembly overview - cylinder head
  109
• 2.2 Assembly overview - camshaft housing
  111
• 2.3 Removing and installing cylinder head
  112
• 2.4 Removing and installing camshaft housing
  116
• 2.5 Checking compression
  120
• 3 Valve gear
  123
• 3.1 Assembly overview - valve gear
  123
• 3.2 Removing and installing camshaft control valve 1 N205 / N318
  124
• 3.3 Removing and installing cam actuators
  125
• 3.4 Removing and installing camshaft adjuster
  128
• 3.5 Measuring axial play of camshaft
  129
• 3.6 Removing and installing camshaft oil seal
  130
• 3.7 Removing and installing valve stem seals
  135
• 4 Inlet and exhaust valves
  144
• 4.1 Checking valve guides
  144
• 4.2 Checking valves
  144
• 4.3 Valve dimensions
  145
• Lubrication
  146
• 1 Sump, oil pump
  146
• 1.1 Assembly overview - sump, oil pump
  146
• 1.2 Removing and installing oil level and oil temperature sender G266
  149
• 1.3 Removing and installing lower part of sump
  149
• 1.4 Removing and installing oil pump
  152
• 1.5 Removing and installing upper part of sump
  153
• 1.6 Engine oil
  156
• 2 Engine oil cooler
  157
• 2.1 Assembly overview - engine oil cooler
  157
• 2.2 Removing and installing engine oil cooler
  157
• 3 Crankcase breather
  159
• 3.1 Assembly overview - crankcase breather system
  159
• 3.2 Removing and installing oil separator
  160
• 4 Oil filter, oil pressure switch
  162
• 4.1 Assembly overview - oil filter/oil pressure switch
  162
• 4.2 Removing and installing oil pressure switch F1
  163
• 4.3 Removing and installing oil pressure switch for reduced oil pressure F378
  164
• 4.4 Removing and installing oil pressure regulating valve N428
  165
• 4.5 Checking oil pressure
  166
• Cooling
  169
• 1 Cooling system, coolant
  169
• 1.1 Coolant hose schematic diagram
  169
• 1.2 Draining and filling coolant
  172
• 1.3 Checking cooling system for leaks
  178
• 2 Coolant pump, regulation of cooling system
  181
• 2.1 Assembly overview - coolant pump, thermostat
  181
• 2.2 Assembly overview - electric coolant pump
  183
• 2.3 Assembly overview - coolant temperature sender
  185
• 2.4 Removing and installing coolant pump
  186
• 2.5 Removing and installing toothed belt pulley for coolant pump
  190
• 2.6 Removing and installing thermostat
  194
• 2.7 Removing and installing electric coolant pump
  197
• 2.8 Removing and installing coolant temperature sender G62
  199
• 3 Coolant pipes
  202
• 3.1 Assembly overview - coolant pipes
  202
• 3.2 Removing and installing coolant pipes
  202
• 4 Radiator, radiator fan
  206
• 4.1 Assembly overview - radiator/radiator fan
  206
• 4.2 Assembly overview - radiator cowl and radiator fan
  208
• 4.3 Removing and installing radiator
  210
• 4.4 Removing and installing cooler for charge air cooling circuit
  213
• 4.5 Removing and installing radiator cowling with radiator fan
  217
• 4.6 Removing and installing radiator fan V7
  218
• Turbocharging/supercharging
  220
• 1 Turbocharger
  220
• 1.1 Assembly overview - turbocharger
  220
• 1.2 Removing and installing turbocharger
  222
• 1.3 Removing and installing charge pressure positioner V465
  226
• 2 Charge air system
  230
• 2.1 Assembly overview - charge air system
  230
• 2.2 Removing and installing charge pressure sender GX26
  232
• 2.3 Removing and installing charge air cooler
  232
• 2.4 Checking charge air system for leaks
  234
• Mixture preparation - injection
  236
• 1 Injection system
  236
• 1.1 Overview of fitting locations - injection system
  236
• 1.2 Releasing high pressure in fuel system
  239
• 2 Air filter
  241
• 2.1 Assembly overview - air filter housing
  241
• 2.2 Removing and installing air filter housing
  242
• 3 Intake manifold
  243
• 3.1 Assembly overview - intake manifold
  243
• 3.2 Removing and installing intake manifold
  245
• 3.3 Removing and installing throttle valve module GX3
  247
• 3.4 Cleaning throttle valve module GX3
  249
• 4 Injectors
  250
• 4.1 Assembly overview - fuel rail with injectors
  250
• 4.2 Removing and installing fuel rail
  251
• 4.3 Removing and installing injectors
  252
• 4.4 Cleaning injectors
  256
• 5 Senders and sensors
  258
• 5.1 Removing and installing intake manifold sender GX9
  258
• 5.2 Removing and installing fuel pressure sender G247
  258
• 5.3 Checking fuel pressure sender G247
  259
• 6 High-pressure pump
  263
• 6.1 Assembly overview - high-pressure pump
  263
• 6.2 Removing and installing high-pressure pump
  264
• 6.3 Removing and installing high-pressure pipe
  265
• 7 Lambda probe
  267
• 7.1 Assembly overview - Lambda probe
  267
• 7.2 Removing and installing Lambda probe
  268
• 8 Engine control unit
  270
• 8.1 Removing and installing engine control unit J623
  270
• 8.2 Removing and installing engine control unit J623 with protective housing
  271
• Exhaust system
  273
• 1 Exhaust pipes, silencers
  273
• 1.1 Assembly overview - silencers
  273
• 1.2 Removing and installing silencer
  274
• 1.3 Separating exhaust pipes, silencers
  275
• 1.4 Aligning exhaust system free of stress
  276
• 1.5 Checking exhaust system for leaks
  277
• 2 Emission control
  278
• 2.1 Assembly overview - emission control
  278
• 2.2 Removing and installing catalytic converter
  279
• Ignition system
  284
• 1 Ignition system
  284
• 1.1 Assembly overview - ignition system
  284
• 1.2 Test data, spark plugs
  285
• 1.3 Removing and installing ignition coils with output stage
  285
• 1.4 Removing and installing knock sensor 1 G61
  287
• 1.5 Removing and installing Hall sender
  288
• 1.6 Removing and installing engine speed sender G28
  290