4-cylinder injection engine (1.4 l engine, natural gas)

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety precautions when working on vehicles with a gas system
  1
• 1.2 Safety regulations for working on fuel supply
  3
• 1.3 Safety measures when working on vehicles with start/stop system
  4
• 1.5 Safety precautions when working on the cooling system
  4
• 1.6 Safety precautions when working on ignition system
  4
• 1.7 Safety precautions when working on exhaust system
  5
• 2 Identification
  6
• 2.1 Engine number/engine data
  6
• 3 Repair instructions
  8
• 3.1 Rules for cleanliness
  8
• 3.2 General information
  9
• 3.3 Foreign objects in engine
  11
• 3.4 Contact corrosion
  12
• 3.5 Routing and attachment of lines
  12
• 3.6 Fitting radiator and condensers
  12
• 3.7 Checking vacuum system
  12
• Removing and installing engine
  14
• 1 Removing and installing engine
  14
• 1.1 Removing engine
  14
• 1.2 Separating engine and gearbox
  26
• 1.3 Securing engine on engine and gearbox support
  30
• 1.4 Installing engine
  31
• 2 Assembly mountings
  37
• 2.1 Assembly overview - assembly mountings
  37
• 2.2 Removing and installing engine mounting
  40
• 2.3 Removing and installing gearbox mounting
  42
• 2.4 Removing and installing pendulum support
  43
• 2.5 Supporting engine in installation position
  45
• 2.6 Adjusting assembly mountings
  47
• 2.7 Checking adjustment of assembly mountings
  50
• Crankshaft group
  52
• 1 Cylinder block (pulley end)
  52
• 1.1 Assembly overview - poly V-belt drive
  52
• 1.2 Assembly overview - sealing flange, belt pulley end
  56
• 1.3 Removing and installing poly-V belt
  58
• 1.4 Removing and installing tensioner for poly V-belt
  63
• 1.5 Removing and installing vibration damper
  64
• 1.6 Removing and installing engine support
  65
• 1.7 Renewing crankshaft oil seal - belt pulley end
  68
• 1.8 Removing and installing sealing flange on pulley end
  71
• 2 Cylinder block, gearbox end
  76
• 2.1 Assembly overview - cylinder block, gearbox end
  76
• 2.2 Removing and installing flywheel
  77
• 2.3 Removing and installing sealing flange on gearbox side
  78
• 3 Crankshaft
  91
• 3.1 Crankshaft dimensions
  91
• 3.2 Measuring axial clearance of crankshaft
  91
• 3.3 Renewing needle bearing in crankshaft
  92
• 4 Pistons and conrods
  95
• 4.1 Assembly overview - pistons and conrods
  95
• 4.2 Removing and installing pistons
  98
• 4.3 Checking pistons and cylinder bores
  99
• 4.4 Separating new conrod
  101
• 4.5 Checking radial clearance of conrods
  102
• 4.6 Removing and installing oil spray jets
  102
• Cylinder head, valve gear
  104
• 1 Cylinder head
  104
• 1.1 Assembly overview - cylinder head
  104
• 1.2 Assembly overview - camshaft housing
  107
• 1.3 Removing and installing cylinder head
  110
• 1.4 Removing and installing camshaft housing
  115
• 1.5 Checking compression
  122
• 2 Toothed belt drive
  125
• 2.1 Assembly overview - toothed belt cover
  125
• 2.2 Assembly overview - toothed belt
  125
• 2.3 Removing and installing toothed belt
  127
• 2.4 Checking valve timing
  136
• 2.5 Removing toothed belt from camshaft
  143
• 3 Valve gear
  162
• 3.1 Assembly overview - valve gear
  162
• 3.2 Measuring axial play of camshaft
  164
• 3.3 Removing and installing camshaft oil seal
  165
• 3.4 Removing and installing camshaft adjuster
  174
• 3.5 Removing and installing camshaft control valve 1 N205
  176
• 3.6 Removing and installing valve stem seals
  177
• 4 Inlet and exhaust valves
  186
• 4.1 Reworking valve seats
  186
• 4.2 Checking valve guides
  188
• 4.3 Checking valves
  189
• 4.4 Valve dimensions
  189
• Lubrication
  191
• 1 Sump, oil pump
  191
• 1.1 Assembly overview - sump/oil pump
  191
• 1.2 Engine oil:
  195
• 1.3 Removing and installing lower part of sump
  196
• 1.4 Removing and installing upper part of sump
  200
• 1.5 Removing and installing oil pump
  204
• 1.6 Removing and installing oil level and oil temperature sender G266
  205
• 2 Engine oil cooler
  207
• 2.1 Assembly overview - engine oil cooler
  207
• 2.2 Removing and installing engine oil cooler
  207
• 3 Crankcase ventilation
  209
• 3.1 Assembly overview - crankcase breather system
  209
• 3.2 Removing and installing oil separator
  210
• 4 Oil filter, oil pressure switch
  214
• 4.1 Assembly overview - oil filter/oil pressure switch
  214
• 4.2 Removing and installing oil pressure switch F1
  216
• 4.3 Removing and installing oil pressure switch for reduced oil pressure F378
  218
• 4.4 Checking oil pressure
  219
• 4.5 Removing and installing oil pressure regulating valve N428
  221
• Cooling
  223
• 1 Cooling system/coolant
  223
• 1.1 Connection diagram - coolant hoses
  223
• 1.2 Checking cooling system for leaks
  225
• 1.3 Draining and adding coolant
  227
• 2 Coolant pump, regulation of cooling system
  234
• 2.1 Assembly overview - coolant pump, thermostat
  234
• 2.2 Assembly overview - electric coolant pump
  237
• 2.3 Assembly overview - coolant temperature sender
  237
• 2.4 Removing and installing electric coolant pump
  238
• 2.5 Removing and installing coolant pump
  240
• 2.6 Removing and installing thermostat
  245
• 2.7 Removing and installing toothed belt pulley for coolant pump
  249
• 2.8 Removing and installing coolant temperature sender G62
  250
• 2.9 Removing and installing radiator outlet coolant temperature sender G83
  252
• 3 Coolant pipes
  255
• 3.1 Assembly overview - coolant pipes
  255
• 3.2 Removing and installing coolant pipes
  255
• 4 Radiator, radiator fan
  258
• 4.1 Assembly overview - radiator/radiator fan
  258
• 4.2 Assembly overview – radiator cowl and radiator fan
  260
• 4.3 Removing and installing radiator
  261
• 4.4 Removing and installing radiator cowl
  265
• 4.5 Removing and installing radiator fan VX57
  266
• 4.6 Removing and installing radiator fan 2 V177
  267
• Turbocharging/supercharging
  269
• 1 Turbocharger
  269
• 1.1 Assembly overview - turbocharger
  269
• 1.2 Removing and installing turbocharger
  271
• 1.3 Removing and installing charge pressure positioner V465
  276
• 2 Charge air system
  278
• 2.1 Assembly overview - charge air system
  278
• 2.2 Removing and installing charge pressure sender GX26
  281
• 2.3 Removing and installing charge air cooler
  281
• 2.4 Checking charge air system for leaks
  283
• 2.5 Removing and installing air pipe
  286
• Mixture preparation - injection
  288
• 1 Injection system
  288
• 1.1 Overview of fitting locations - injection system
  288
• 1.2 Releasing high pressure in fuel system
  292
• 2 Injectors
  293
• 2.1 Assembly overview - fuel rail with injectors
  293
• 2.2 Removing and installing fuel rail
  295
• 2.3 Removing and installing injectors
  296
• 2.4 Renewing seals on injectors
  301
• 2.5 Cleaning injectors
  306
• 3 Gas injectors
  308
• 3.1 Assembly overview - gas rail
  308
• 3.2 Removing and installing gas rail with gas injector N366/N367/N368/N369
  310
• 3.3 Removing and installing gas rail temperature and pressure sensor GX21
  312
• 4 Gas pressure regulator
  315
• 4.1 Assembly overview - gas pressure regulator
  315
• 4.2 Removing and installing gas pressure regulator
  317
• 4.3 Removing and installing tank pressure sensor G400
  320
• 5 Air filter
  322
• 5.1 Assembly overview - air filter housing
  322
• 5.2 Removing and installing air filter housing
  324
• 6 Intake manifold
  325
• 6.1 Assembly overview – intake manifold
  325
• 6.2 Removing and installing intake manifold
  328
• 6.3 Removing and installing throttle valve module GX3
  331
• 6.4 Cleaning throttle valve module GX3
  333
• 7 Senders and sensors
  334
• 7.1 Removing and installing fuel pressure sender G247
  334
• 7.2 Checking fuel pressure sender G247
  335
• 7.3 Removing and installing intake manifold sender GX9
  337
• 8 Engine control unit
  339
• 8.1 Removing and installing engine (motor) control unit J623 with protective housing
  339
• 9 High-pressure pump
  342
• 9.1 Assembly overview - high-pressure pump
  342
• 9.2 Removing and installing high-pressure pump
  343
• 9.3 Removing and installing high-pressure pipe
  345
• 10 Lambda probe
  348
• 10.1 Assembly overview - Lambda probe
  348
• 10.2 Removing and installing Lambda probe
  349
• Exhaust system
  351
• 1 Exhaust pipes and silencers
  351
• 1.1 Assembly overview – silencers
  351
• 1.2 Removing and installing silencer
  351
• 1.3 Aligning exhaust system free of stress
  352
• 1.4 Checking exhaust system for leaks
  353
• 2 Emission control
  354
• 2.1 Assembly overview – emission control
  354
• 2.2 Removing and installing catalytic converter
  356
• Ignition system
  361
• 1 Ignition system
  361
• 1.1 Assembly overview - ignition system
  361
• 1.2 Test data, spark plugs
  362
• 1.3 Removing and installing ignition coils with output stage
  363
• 1.4 Removing and installing knock sensor 1 G61
  365
• 1.5 Removing and installing Hall sender G40
  366
• 1.6 Removing and installing engine speed sender G28
  366