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
  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
  7
• 3.1 Rules for cleanliness
  7
• Removing and installing engine
  8
• 1 Removing and installing engine
  8
• 1.1 Removing engine
  8
• 1.2 Installing engine
  17
• 2 Assembly mountings
  21
• 2.1 Assembly overview - assembly mountings
  21
• Crankshaft group
  23
• 1 Cylinder block (pulley end)
  23
• 1.1 Assembly overview - poly V-belt drive
  23
• 1.2 Assembly overview - cylinder block (pulley end)
  25
• 1.3 Removing and installing poly V-belt
  28
• 1.4 Removing and installing ancillary bracket
  30
• 1.5 Removing and installing poly V-belt pulley
  31
• 1.6 Renewing crankshaft oil seal - belt pulley end
  33
• 2 Cylinder block, gearbox end
  37
• 2.1 Assembly overview - cylinder block, gearbox end
  37
• 2.2 Removing and installing sealing flange on gearbox side
  38
• 3 Crankshaft
  47
• 3.1 Assembly overview - crankshaft
  47
• 3.2 Renewing needle bearing in crankshaft
  48
• 3.3 Crankshaft dimensions
  49
• 4 Pistons and conrods
  50
• 4.1 Assembly overview - pistons and conrods
  50
• 4.2 Checking piston and cylinder bore
  52
• 4.3 Separating new conrod
  53
• 4.4 Removing and installing pistons
  53
• 4.5 Removing and installing oil spray jets
  54
• Cylinder head, valve gear
  56
• 1 Cylinder head
  56
• 1.1 Assembly overview - cylinder head
  56
• 1.2 Removing and installing cylinder head
  59
• 1.3 Removing and installing camshaft housing
  61
• 1.4 Checking compression
  67
• 2 Cover for timing chain
  70
• 2.1 Removing and installing valve timing housing
  70
• 3 Chain drive
  74
• 3.1 Removing and installing timing chain and chain drive for oil pump
  74
• 3.2 Checking valve timing
  82
• 3.3 Adjusting valve timing
  85
• 3.4 Checking timing chain
  92
• 4 Valve gear
  100
• 4.1 Assembly overview - valve gear
  100
• 4.2 Measuring axial clearance of camshaft
  101
• 4.3 Removing and installing valve stem seals
  102
• 5 Inlet and exhaust valves
  105
• 5.1 Reworking valve seats
  105
• 5.2 Checking valve guides
  106
• Lubrication
  107
• 1 Sump, oil pump
  107
• 1.1 Assembly overview - sump / oil pump
  107
• 1.2 Engine oil
  110
• 1.3 Removing and installing oil sump
  110
• 1.4 Removing and installing oil pump
  112
• 2 Oil filter, oil pressure switch
  115
• 2.1 Checking oil pressure and oil pressure switch
  115
• Cooling
  117
• 1 Cooling system, coolant
  117
• 1.1 Coolant hose schematic diagram
  117
• 1.2 Assembly overview - engine preheater
  119
• 1.3 Removing and installing engine preheater heater element Z97
  120
• 1.4 Checking cooling system for leaks
  122
• 1.5 Draining and filling coolant
  124
• 2 Coolant pump, regulation of cooling system
  130
• 2.1 Assembly overview - coolant pump, thermostat
  130
• 2.2 Electric coolant pump
  132
• 2.3 Removing and installing coolant pump
  133
• 2.4 Removing and installing coolant pump pulley
  140
• 3 Radiator, radiator fan
  148
• 3.1 Assembly overview - radiator/radiator fan
  148
• 3.2 Removing and installing radiator
  149
• 3.3 Removing and installing radiator cowling
  151
• 3.4 Removing and installing radiator module
  152
• Turbocharging/supercharging
  153
• 1 Turbocharger
  153
• 1.1 Assembly overview - turbocharger
  153
• 1.2 Removing and installing turbocharger
  157
• 1.3 Checking vacuum unit for turbocharger
  162
• 1.4 Adjusting vacuum unit for turbocharger
  164
• 1.5 Renewing vacuum unit for turbocharger
  169
• 2 Charge air system
  172
• 2.1 Assembly overview - charge air system
  172
• 2.2 Removing and installing charge air cooler
  175
• 2.3 Checking charge air system for leaks
  179
• 3 Supercharger
  182
• 3.1 Assembly overview - supercharger
  182
• 3.2 Removing and installing supercharger
  184
• 3.3 Removing and installing drive unit seal for supercharger
  191
• Mixture preparation - injection
  195
• 1 Injectors
  195
• 1.1 Assembly overview - fuel rail with injectors
  195
• 1.2 Removing and installing injectors
  197
• 1.3 Renewing seals on injectors
  199
• 2 Air filter
  204
• 2.1 Assembly overview - air filter housing
  204
• 2.2 Removing and installing air filter housing
  205
• 3 Intake manifold
  206
• 3.1 Assembly overview - intake manifold
  206
• 3.2 Removing and installing throttle valve module
  211
• 3.3 Cleaning throttle valve module
  213
• 3.4 Removing and installing regulating flap control unit
  214
• 4 Senders and sensors
  217
• 4.1 Checking fuel pressure sender
  217
• 5 Engine control unit
  221
• 5.1 Removing and installing engine control unit
  221
• 5.2 Removing and installing engine control unit with protective housing
  222
• 6 High-pressure pump
  225
• 6.1 Assembly overview - high-pressure pump
  225
• 6.2 Removing and installing high-pressure pump
  226
• Exhaust system
  230
• 1 Exhaust pipes, silencers
  230
• 1.1 Assembly overview - silencers
  230
• 1.2 Removing and installing front exhaust pipe
  232
• 1.3 Separating exhaust pipes, silencers
  233
• 1.4 Aligning exhaust system free of stress
  235
• 1.5 Installation position of clamp
  236
• 2 Cleansing exhaust emissions
  237
• 2.1 Assembly overview - emission control
  237
• 2.2 Removing and installing catalytic converter
  238
• Ignition system
  241
• 1 Ignition system
  241
• 1.1 Assembly overview - ignition system
  241
• 1.2 Test data, spark plugs
  242
• 1.3 Removing and installing ignition coils with output stage
  242
• 1.4 Removing and installing engine speed sender
  244