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

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety regulations for working on fuel supply
  1
• 1.2 Safety measures when working on vehicles with start/stop system
  1
• 1.4 Safety precautions when working on the cooling system
  2
• 1.5 Safety precautions when working on ignition system
  2
• 1.6 Safety precautions when working on exhaust system
  3
• 2 Identification
  4
• 2.1 Engine number/engine data
  4
• 3 Repair instructions
  6
• 3.1 Rules for cleanliness
  6
• 3.2 General information
  7
• 3.3 Foreign objects in engine
  7
• 3.4 Contact corrosion
  8
• 3.5 Routing and attachment of lines
  8
• 3.6 Fitting radiator and condensers
  8
• 3.7 Checking vacuum system
  8
• Removing and installing engine
  10
• 1 Removing and installing engine
  10
• 1.1 Removing engine
  10
• 1.2 Separating engine and gearbox
  20
• 1.3 Securing engine on engine and gearbox support
  25
• 1.4 Installing engine
  26
• 2 Assembly mountings
  32
• 2.1 Assembly overview - assembly mountings
  32
• 2.2 Removing and installing engine mounting
  34
• 2.3 Removing and installing gearbox mounting
  36
• 2.4 Removing and installing pendulum support
  37
• 2.5 Supporting engine in installation position
  39
• 2.6 Adjusting assembly mountings
  42
• 2.7 Checking adjustment of assembly mountings
  44
• Crankshaft group
  46
• 1 Cylinder block (pulley end)
  46
• 1.1 Assembly overview - poly V-belt drive
  46
• 1.2 Assembly overview - sealing flange, belt pulley end
  50
• 1.3 Removing and installing poly-V belt
  52
• 1.4 Removing and installing tensioner for poly V-belt
  56
• 1.5 Removing and installing vibration damper
  57
• 1.6 Removing and installing engine support
  58
• 1.7 Renewing crankshaft oil seal - belt pulley end
  61
• 1.8 Removing and installing sealing flange on pulley end
  64
• 2 Cylinder block, gearbox end
  68
• 2.1 Assembly overview - cylinder block, gearbox end
  68
• 2.2 Removing and installing flywheel
  69
• 2.3 Removing and installing sealing flange on gearbox side
  70
• 3 Crankshaft
  81
• 3.1 Crankshaft dimensions
  81
• 3.2 Renewing needle bearing in crankshaft
  81
• 3.3 Measuring axial clearance of crankshaft
  84
• 4 Pistons and conrods
  86
• 4.1 Assembly overview - pistons and conrods
  86
• 4.2 Removing and installing pistons
  89
• 4.3 Checking pistons and cylinder bores
  90
• 4.4 Separating new conrod
  92
• 4.5 Checking radial clearance of conrods
  93
• 4.6 Removing and installing oil spray jets
  93
• Cylinder head, valve gear
  95
• 1 Cylinder head
  95
• 1.1 Assembly overview - cylinder head
  95
• 1.2 Assembly overview - camshaft housing
  98
• 1.3 Removing and installing cylinder head
  102
• 1.4 Removing and installing camshaft housing
  107
• 1.5 Checking compression
  112
• 2 Toothed belt drive
  115
• 2.1 Assembly overview - toothed belt cover
  115
• 2.2 Assembly overview - toothed belt
  115
• 2.3 Removing and installing toothed belt
  119
• 2.4 Checking valve timing
  132
• 2.5 Removing toothed belt from camshaft
  139
• 3 Valve gear
  151
• 3.1 Assembly overview - valve gear
  151
• 3.2 Measuring axial play of camshaft
  153
• 3.3 Removing and installing camshaft oil seal
  154
• 3.4 Removing and installing camshaft adjuster
  162
• 3.5 Removing and installing camshaft control valve 1 N205
  172
• 3.6 Removing and installing exhaust camshaft control valve 1 N318
  173
• 3.7 Removing and installing valve stem seals
  174
• 4 Inlet and exhaust valves
  184
• 4.1 Reworking valve seats
  184
• 4.2 Checking valve guides
  186
• 4.3 Checking valves
  187
• 4.4 Valve dimensions
  187
• Lubrication
  188
• 1 Sump, oil pump
  188
• 1.1 Assembly overview - sump/oil pump
  188
• 1.2 Engine oil:
  191
• 1.3 Removing and installing lower part of sump
  192
• 1.4 Removing and installing upper part of sump
  197
• 1.5 Removing and installing oil pump
  202
• 1.6 Removing and installing oil level and oil temperature sender G266
  203
• 2 Engine oil cooler
  204
• 2.1 Assembly overview - engine oil cooler
  204
• 2.2 Removing and installing engine oil cooler
  204
• 3 Crankcase ventilation
  206
• 3.1 Assembly overview - crankcase breather system
  206
• 3.2 Removing and installing oil separator
  207
• 4 Oil filter, oil pressure switch
  211
• 4.1 Assembly overview - oil filter/oil pressure switch
  211
• 4.2 Removing and installing oil pressure switch F1
  212
• 4.3 Removing and installing oil pressure switch for reduced oil pressure F378
  214
• 4.4 Checking oil pressure and oil pressure switch
  215
• 4.5 Removing and installing oil pressure regulating valve N428
  218
• Cooling
  219
• 1 Cooling system/coolant
  219
• 1.1 Connection diagram - coolant hoses
  219
• 1.2 Checking cooling system for leaks
  221
• 1.3 Draining and adding coolant
  223
• 2 Coolant pump, regulation of cooling system
  230
• 2.1 Assembly overview - coolant pump, thermostat
  230
• 2.2 Assembly overview - electric coolant pump
  233
• 2.3 Assembly overview - coolant temperature sender
  234
• 2.4 Removing and installing electric coolant pump
  235
• 2.5 Removing and installing coolant pump
  237
• 2.6 Removing and installing thermostat
  242
• 2.7 Removing and installing toothed belt pulley for coolant pump
  246
• 2.8 Removing and installing coolant temperature sender G62
  248
• 2.9 Removing and installing radiator outlet coolant temperature sender G83
  250
• 3 Coolant pipes
  252
• 3.1 Assembly overview - coolant pipes
  252
• 3.2 Removing and installing coolant pipes
  252
• 4 Radiator, radiator fan
  257
• 4.1 Assembly overview - radiator/radiator fan
  257
• 4.2 Assembly overview – radiator cowl and radiator fan
  259
• 4.3 Removing and installing radiator
  260
• 4.4 Removing and installing radiator cowl with radiator fan
  264
• 4.5 Removing and installing radiator fan VX57
  265
• 4.6 Removing and installing radiator fan 2 V177
  266
• Turbocharging/supercharging
  267
• 1 Turbocharger
  267
• 1.1 Assembly overview - turbocharger
  267
• 1.2 Removing and installing turbocharger
  268
• 1.3 Removing and installing charge pressure positioner V465
  273
• 2 Charge air system
  274
• 2.1 Assembly overview - charge air system
  274
• 2.2 Removing and installing charge air cooler
  277
• 2.3 Removing and installing charge pressure sender GX26
  280
• 2.4 Checking charge air system for leaks
  280
• 2.5 Removing and installing air pipe
  282
• Mixture preparation - injection
  285
• 1 Injection system
  285
• 1.1 Overview of fitting locations - injection system
  285
• 2 Injectors
  289
• 2.1 Assembly overview - fuel rail with injectors
  289
• 2.2 Removing and installing fuel rail
  291
• 2.3 Removing and installing injectors
  291
• 2.4 Renewing seals on injectors
  296
• 2.5 Cleaning injectors
  303
• 3 Air filter
  305
• 3.1 Assembly overview - air filter housing
  305
• 3.2 Removing and installing air filter housing
  307
• 4 Intake manifold
  308
• 4.1 Assembly overview – intake manifold
  308
• 4.2 Removing and installing intake manifold
  310
• 4.3 Removing and installing throttle valve module GX3
  312
• 4.4 Cleaning throttle valve module GX3
  313
• 5 Senders and sensors
  315
• 5.1 Removing and installing fuel pressure sender G247
  315
• 5.2 Checking fuel pressure sender G247
  316
• 6 Engine control unit
  319
• 6.1 Removing and installing engine (motor) control unit J623 with protective housing
  319
• 7 High-pressure pump
  322
• 7.1 Assembly overview - high-pressure pump
  322
• 7.2 Removing and installing high-pressure pump
  323
• 7.3 Removing and installing high-pressure pipe
  324
• 8 Lambda probe
  327
• 8.1 Assembly overview - Lambda probe
  327
• 8.2 Removing and installing Lambda probe
  328
• Exhaust system
  330
• 1 Exhaust pipes and silencers
  330
• 1.1 Assembly overview – silencers
  330
• 1.2 Separating exhaust pipes from silencers
  331
• 1.3 Aligning exhaust system free of stress
  333
• 1.4 Checking exhaust system for leaks
  334
• 1.5 Installation position of clamp
  334
• 2 Emission control
  337
• 2.1 Assembly overview – emission control
  337
• 2.2 Removing and installing catalytic converter
  340
• Ignition system
  344
• 1 Ignition system
  344
• 1.1 Assembly overview - ignition system
  344
• 1.2 Removing and installing ignition coils with output stage
  346
• 1.3 Removing and installing knock sensor 1 G61
  348
• 1.4 Removing and installing Hall sender
  349
• 1.5 Removing and installing engine speed sender G28
  351