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

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 Installing engine
  15
• 2 Assembly mountings
  19
• 2.1 Assembly overview - assembly mountings
  19
• Crankshaft group
  21
• 1 Cylinder block (pulley end)
  21
• 1.1 Assembly overview - poly V-belt drive
  21
• 1.2 Assembly overview - cylinder block (pulley end)
  23
• 1.3 Removing and installing poly V-belt
  26
• 1.4 Removing and installing ancillary bracket
  28
• 1.5 Removing and installing belt pulley
  29
• 1.6 Renewing crankshaft oil seal - belt pulley end
  31
• 2 Cylinder block, gearbox end
  35
• 2.1 Assembly overview - cylinder block, gearbox end
  35
• 2.2 Removing and installing sealing flange on gearbox side
  36
• 3 Crankshaft
  45
• 3.1 Assembly overview - crankshaft
  45
• 3.2 Renewing needle bearing in crankshaft
  46
• 3.3 Crankshaft dimensions
  47
• 4 Pistons and conrods
  48
• 4.1 Assembly overview - pistons and conrods
  48
• 4.2 Removing and installing pistons
  49
• 4.3 Removing and installing oil spray jets
  50
• 4.4 Checking piston and cylinder bore
  52
• 4.5 Separating new conrod
  53
• Cylinder head, valve gear
  54
• 1 Cylinder head
  54
• 1.1 Assembly overview - cylinder head
  54
• 1.2 Removing and installing cylinder head
  57
• 1.3 Removing and installing camshaft housing
  59
• 1.4 Checking compression
  65
• 2 Cover for timing chain
  68
• 2.1 Removing and installing valve timing housing
  68
• 3 Chain drive
  72
• 3.1 Removing and installing timing chain and chain drive for oil pump
  72
• 3.2 Checking valve timing
  80
• 3.3 Adjusting valve timing
  83
• 3.4 Checking timing chain
  90
• 4 Valve gear
  98
• 4.1 Assembly overview - valve gear
  98
• 4.2 Measuring axial play of camshaft
  99
• 4.3 Removing and installing valve stem seals
  100
• 5 Inlet and exhaust valves
  103
• 5.1 Reworking valve seats
  103
• 5.2 Checking valve guides
  104
• Lubrication
  105
• 1 Sump, oil pump
  105
• 1.1 Assembly overview - sump / oil pump
  105
• 1.2 Engine oil
  108
• 1.3 Removing and installing oil sump
  108
• 1.4 Removing and installing oil pump
  110
• 2 Oil filter, oil pressure switch
  114
• 2.1 Checking oil pressure and oil pressure switch
  114
• Cooling
  116
• 1 Cooling system, coolant
  116
• 1.1 Coolant hose schematic diagram
  116
• 1.2 Checking cooling system for leaks
  118
• 1.3 Draining and filling coolant
  119
• 2 Coolant pump, regulation of cooling system
  125
• 2.1 Assembly overview - thermostat
  125
• 2.2 Removing and installing electric coolant pump
  126
• 2.3 Removing and installing coolant pump
  127
• 2.4 Removing and installing coolant pump pulley
  134
• 3 Radiator, radiator fan
  141
• 3.1 Assembly overview - radiator/radiator fan
  141
• 3.2 Removing and installing radiator
  142
• 3.3 Removing and installing radiator cowling
  144
• 3.4 Removing and installing radiator module
  145
• Turbocharging/supercharging
  146
• 1 Turbocharger
  146
• 1.1 Assembly overview - turbocharger
  146
• 1.2 Removing and installing turbocharger
  150
• 1.3 Checking vacuum unit for turbocharger
  155
• 1.4 Adjusting vacuum unit for turbocharger
  157
• 1.5 Renewing vacuum unit for turbocharger
  162
• 2 Charge air system
  165
• 2.1 Assembly overview - charge air system
  165
• 2.2 Removing and installing charge air cooler
  168
• 2.3 Checking charge air system for leaks
  171
• 3 Supercharger
  175
• 3.1 Assembly overview - supercharger
  175
• 3.2 Removing and installing supercharger
  177
• 3.3 Removing and installing supercharger input shaft seal
  184
• Mixture preparation - injection
  188
• 1 Injection system
  188
• 1.1 Releasing high pressure in fuel system
  188
• 2 Injectors
  189
• 2.1 Assembly overview - fuel rail with injectors
  189
• 2.2 Removing and installing injectors
  191
• 2.3 Renewing seals on injectors
  193
• 3 Air filter
  198
• 3.1 Assembly overview - air filter housing
  198
• 3.2 Removing and installing air filter housing
  199
• 4 Intake manifold
  200
• 4.1 Assembly overview - intake manifold
  200
• 4.2 Removing and installing throttle valve module J338
  205
• 4.3 Cleaning throttle valve module
  207
• 4.4 Removing and installing regulating flap control unit J808
  208
• 5 Senders and sensors
  211
• 5.1 Checking fuel pressure sender G247
  211
• 6 Engine control unit
  215
• 6.1 Removing and installing engine control unit J623
  215
• 6.2 Removing and installing engine control unit J623 with protective housing
  216
• 7 High-pressure pump
  219
• 7.1 Assembly overview - high-pressure pump
  219
• 7.2 Removing and installing high-pressure pump
  220
• Exhaust system
  224
• 1 Exhaust pipes, silencers
  224
• 1.1 Assembly overview - silencers
  224
• 1.2 Removing and installing front exhaust pipe
  225
• 1.3 Separating exhaust pipes, silencers
  227
• 1.4 Aligning exhaust system free of stress
  228
• 1.5 Installation position of clamp
  229
• 2 Emission control
  231
• 2.1 Assembly overview - emission control
  231
• 2.2 Removing and installing catalytic converter
  232
• Ignition system
  235
• 1 Ignition system
  235
• 1.1 Assembly overview - ignition system
  235
• 1.2 Test data, spark plugs
  236
• 1.3 Removing and installing ignition coils with output stage
  236
• 1.4 Removing and installing engine speed sender G28
  238