4-cylinder injection engine (1.6 l, 4V, EA211, MPI)

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 a start/stop system
  1
• 1.4 Safety precautions when working on ignition system
  2
• 1.5 Safety precautions when working on the cooling system
  2
• 2 Identification
  3
• 2.1 Engine number/engine data
  3
• 3 Repair instructions
  5
• 3.1 Rules for cleanliness
  5
• 3.2 Foreign objects in engine
  5
• 3.3 Contact corrosion
  5
• 3.4 Routing and attachment of lines
  5
• 3.5 Fitting radiator and condensers
  6
• Removing and installing engine
  7
• 1 Removing and installing engine
  7
• 1.1 Removing engine
  7
• 1.2 Separating engine and gearbox
  19
• 1.3 Securing engine on engine and gearbox support
  23
• 1.4 Installing engine
  25
• 2 Assembly mountings
  29
• 2.1 Assembly overview – assembly mountings
  29
• 2.2 Supporting engine in installation position
  32
• 2.3 Removing and installing engine mounting
  36
• 2.4 Removing and installing gearbox mounting
  37
• 2.5 Removing and installing pendulum support
  38
• 2.6 Checking adjustment of assembly mountings
  39
• 2.7 Adjusting assembly mountings
  40
• Crankshaft group
  43
• 1 Cylinder block (pulley end)
  43
• 1.1 Assembly overview - poly V-belt drive
  43
• 1.2 Removing and installing poly-V belt
  47
• 1.3 Removing and installing tensioner for poly V-belt
  52
• 1.4 Removing and installing vibration damper
  53
• 1.5 Removing and installing engine support
  54
• 1.6 Renewing crankshaft oil seal - belt pulley end
  58
• 2 Cylinder block, gearbox end
  62
• 2.1 Assembly overview - cylinder block, gearbox end
  62
• 2.2 Removing and installing flywheel
  66
• 2.3 Removing and installing drive plate
  67
• 2.4 Removing and installing sealing flange on gearbox side
  70
• 3 Crankshaft
  83
• 3.1 Renewing needle bearing in crankshaft
  83
• 3.2 Measuring axial clearance of crankshaft
  85
• 4 Pistons and conrods
  87
• 4.1 Assembly overview - pistons and conrods
  87
• 4.2 Removing and installing pistons
  91
• 4.3 Checking pistons and cylinder bores
  92
• 4.4 Separating new conrod
  94
• 4.5 Checking radial clearance of conrods
  95
• 4.6 Removing and installing oil spray jets
  96
• Cylinder head, valve gear
  98
• 1 Cylinder head
  98
• 1.1 Assembly overview - cylinder head
  98
• 1.2 Assembly overview - camshaft housing
  100
• 1.3 Removing and installing cylinder head
  102
• 1.4 Removing and installing camshaft housing
  106
• 1.5 Checking compression
  109
• 2 Toothed belt drive
  112
• 2.1 Assembly overview - toothed belt cover
  112
• 2.2 Assembly overview - toothed belt
  112
• 2.3 Checking valve timing
  114
• 2.4 Removing toothed belt from camshaft
  120
• 2.5 Removing and installing toothed belt
  134
• 3 Valve gear
  154
• 3.1 Assembly overview - valve gear
  154
• 3.2 Removing and installing camshaft adjuster
  156
• 3.3 Measuring axial play of camshaft
  163
• 3.4 Removing and installing camshaft oil seal
  164
• 3.5 Removing and installing camshaft control valve 1 N205
  170
• 3.6 Removing and installing valve stem seals
  171
• 4 Inlet and exhaust valves
  181
• 4.1 Checking valve guides
  181
• 4.2 Checking valves
  182
• 4.3 Valve dimensions
  182
• Lubrication
  183
• 1 Sump, oil pump
  183
• 1.1 Assembly overview - sump/oil pump
  183
• 1.2 Removing and installing lower part of sump
  187
• 1.3 Removing and installing oil pump
  190
• 1.4 Removing and installing upper part of sump
  192
• 1.5 Engine oil:
  198
• 2 Engine oil cooler
  199
• 2.1 Assembly overview - engine oil cooler
  199
• 2.2 Removing and installing engine oil cooler
  199
• 3 Crankcase ventilation
  201
• 3.1 Assembly overview - crankcase breather system
  201
• 3.2 Removing and installing oil separator
  202
• 4 Oil filter, oil pressure switch
  205
• 4.1 Assembly overview - oil filter/oil pressure switch
  205
• 4.2 Removing and installing oil pressure switch F1
  205
• 4.3 Checking oil pressure
  206
• 4.4 Removing and installing oil filter housing
  209
• Cooling
  210
• 1 Cooling system/coolant
  210
• 1.1 Connection diagram - coolant hoses
  210
• 1.2 Draining and adding coolant
  211
• 1.3 Checking cooling system for leaks
  218
• 2 Coolant pump, regulation of cooling system
  221
• 2.1 Assembly overview - coolant pump, thermostat
  221
• 2.2 Assembly overview - coolant temperature sender
  224
• 2.3 Removing and installing coolant pump
  225
• 2.4 Removing and installing toothed belt pulley for coolant pump
  229
• 2.5 Removing and installing thermostat
  231
• 2.6 Removing and installing coolant temperature sender G62
  234
• 2.7 Removing and installing radiator outlet coolant temperature sender G83
  235
• 3 Coolant pipes
  237
• 3.1 Assembly overview - coolant pipes
  237
• 3.2 Removing and installing coolant pipes
  237
• 4 Radiator, radiator fan
  240
• 4.1 Assembly overview - radiator/radiator fan
  240
• 4.2 Assembly overview – radiator cowl and radiator fan
  241
• 4.3 Removing and installing radiator
  242
• 4.4 Removing and installing radiator cowl
  245
• 4.5 Removing and installing radiator fan
  245
• Mixture preparation - injection
  247
• 1 Injection system
  247
• 1.1 Overview of fitting locations - injection system
  247
• 1.2 Assembly overview - fuel system
  251
• 2 Injectors
  254
• 2.1 Assembly overview - fuel rail with injectors
  254
• 2.2 Removing and installing fuel rail
  254
• 2.3 Removing and installing injectors
  257
• 2.4 Checking injectors
  258
• 2.5 Cleaning injectors
  262
• 3 Air filter
  264
• 3.1 Assembly overview - air filter housing
  264
• 3.2 Removing and installing air filter housing
  265
• 4 Intake manifold
  267
• 4.1 Assembly overview – intake manifold
  267
• 4.2 Removing and installing intake manifold
  269
• 4.3 Removing and installing throttle valve module GX3
  272
• 4.4 Cleaning throttle valve module GX3
  272
• 5 Senders and sensors
  274
• 5.1 Removing and installing intake manifold sender GX9
  274
• 6 Engine control unit
  275
• 6.1 Removing and installing engine control unit J623
  275
• 7 Lambda probe
  283
• 7.1 Assembly overview - Lambda probe
  283
• 7.2 Removing and installing Lambda probe
  284
• Exhaust system
  287
• 1 Exhaust pipes and silencers
  287
• 1.1 Assembly overview – silencers
  287
• 1.2 Separating exhaust pipes from silencers
  294
• 1.3 Removing and installing silencer
  296
• 1.4 Aligning exhaust system free of stress
  300
• 1.5 Checking exhaust system for leaks
  301
• 2 Emission control
  302
• 2.1 Assembly overview – emission control
  302
• 2.2 Removing and installing catalytic converter
  305
• Ignition system
  308
• 1 Ignition system
  308
• 1.1 Assembly overview - ignition system
  308
• 1.2 Test data, spark plugs
  310
• 1.3 Removing and installing ignition coils with output stage
  310
• 1.4 Removing and installing knock sensor
  312
• 1.5 Removing and installing Hall sender
  313
• 1.6 Removing and installing engine speed sender G28
  314