Content:
4-cylinder direct injection engine (1.5 l engine, 4V, EA 211, turbocharger) – Engine ID: DAC A, DAD A, DAC B, DPB A, DPB E, DPC
Technical data:
1 Safety information
1.1 Safety measures when working on fuel supply
1.2 Safety measures when working on vehicles with a start/stop system
1.3 Safety precautions when using testers and measuring instruments during a road test
1.4 Safety precautions when working on the cooling system
1.5 Safety precautions when working on ignition system
Identification:
2.1 Engine number/engine data
3 Repair instructions
3.1 Rules for cleanliness
3.2 General information
3.3 General repair instructions
3.4 Foreign objects in engine
3.5 Contact corrosion
3.6 Routing and attachment of lines
3.7 Fitting radiator and condensers
3.8 Checking vacuum system
Removing and installing engine:
1 Removing and installing engine
1.1 Removing engine
1.2 Separating engine and gearbox
1.3 Securing engine on engine and gearbox support
1.4 Installing engine
Assembly mountings:
2.1 Assembly overview – assembly mountings
2.2 Removing and installing engine mounting
2.3 Removing and installing gearbox mounting
2.4 Removing and installing pendulum support
2.5 Supporting engine in installation position
2.6 Adjusting assembly mountings
2.7 Checking adjustment of assembly mountings (engine and gearbox mountings)
Engine cover panel:
3.1 Removing and installing engine cover
13 – Crankshaft group
1 Cylinder block (pulley end)
1.1 Assembly overview – poly V-belt drive
1.2 Removing and installing poly-V belt
1.3 Removing and installing tensioner for poly V-belt
1.4 Removing and installing vibration damper
1.5 Removing and installing engine support
1.6 Renewing crankshaft oil seal – belt pulley end
Cylinder block, gearbox end:
2.1 Assembly overview – cylinder block, gearbox end
2.2 Removing and installing flywheel
2.3 Removing and installing sealing flange on gearbox side
Crankshaft:
3.1 Renewing needle bearing in crankshaft
3.2 Crankshaft dimensions
3.3 Measuring axial clearance of crankshaft
Pistons and conrods:
4.1 Assembly overview – pistons and conrods
4.2 Removing and installing pistons
4.3 Checking pistons and cylinder bores
4.4 Separating new conrod
4.5 Checking radial clearance of conrods
4.6 Removing and installing oil spray jets
4.7 Setting piston to TDC position
Cylinder head, valve gear:
1 Cylinder head
1.1 Assembly overview – cylinder head
1.2 Assembly overview – camshaft housing
1.3 Removing and installing cylinder head
1.4 Removing and installing camshaft housing
1.5 Checking compression
Toothed belt drive:
2.1 Assembly overview – toothed belt cover
2.2 Assembly overview – toothed belt
2.3 Assembly overview – valve timing tool
2.4 Removing and installing toothed belt guard
2.5 Removing and installing toothed belt
2.6 Preassembling and installing valve timing tool
2.7 Checking valve timing
2.8 Adjusting valve timing
2.9 Removing toothed belt from camshaft
Valve gear:
3.1 Assembly overview – valve gear
3.2 Removing and installing camshaft oil seal
3.3 Removing and installing camshaft adjuster
3.4 Removing and installing cam actuators
3.5 Removing and installing inlet camshaft control valve 1 N727
3.6 Removing and installing exhaust camshaft control valve 1 N318
3.7 Removing and installing valve stem seals
3.8 Removing and installing holder for oil seal
Inlet and exhaust valves:
4.1 Checking valve guides
4.2 Checking valves
4.3 Valve dimensions
Lubrication:
1 Sump, oil pump
1.1 Assembly overview – sump/oil pump
1.2 Engine oil:
1.3 Removing and installing sump
1.4 Removing and installing oil pump
1.5 Removing and installing oil level and oil temperature sender G266
Engine oil cooler:
2.1 Assembly overview – engine oil cooler
2.2 Removing and installing engine oil cooler
Crankcase ventilation:
3.1 Assembly overview – crankcase breather system
3.2 Removing and installing oil separator
Oil filter, oil pressure switch:
4.1 Assembly overview – oil pressure switches/oil pressure control
4.2 Removing and installing oil pressure sender G10
4.3 Checking oil pressure and oil pressure switch
4.4 Removing and installing oil filter housing
4.5 Removing and installing oil pressure regulating valve N428
Cooling:
1 Cooling system/coolant
1.1 Connection diagram – coolant hoses
1.2 Checking cooling system for leaks
1.3 Draining and adding coolant
1.4 Flushing cooling system
Coolant pump, regulation of cooling system:
2.1 Assembly overview – coolant pump, thermostat
2.2 Assembly overview – electric coolant pump
2.3 Assembly overview – coolant temperature sender
2.4 Removing and installing electric coolant pump
2.5 Removing and installing coolant pump
2.6 Removing and installing toothed belt pulley for coolant pump
2.7 Removing and installing coolant temperature sender G62
2.8 Removing and installing radiator outlet coolant temperature sender G83
2.9 Removing and installing engine outlet coolant temperature sender G82
2.10 Removing and installing engine temperature regulation module GX33
2.11 Checking coolant pump
Coolant pipes:
3.1 Assembly overview – coolant pipes
3.2 Removing and installing coolant pipes
4 Radiator, radiator fan
4.1 Assembly overview – radiator/radiator fan
4.2 Assembly overview – radiator cowl and radiator fan
4.3 Assembly overview – radiator blind
4.4 Removing and installing radiator
4.5 Removing and installing water radiator for charge air cooling circuit
4.6 Removing and installing radiator cowl
4.7 Removing and installing radiator fan
4.8 Removing and installing radiator blind
4.9 Removing and installing radiator blind control motor V544
Turbocharging/supercharging:
1 Turbocharger
1.1 Assembly overview – turbocharger
1.2 Removing and installing turbocharger
1.3 Removing and installing connection for turbocharger
1.4 Removing and installing charge pressure control module GX34
Charge air system:
2.1 Assembly overview – charge air system
2.2 Removing and installing charge air cooler
2.3 Removing and installing charge pressure sender GX26
2.4 Checking charge air system for leaks
2.5 Removing and installing air pipe
2.6 Checking charge air cooler for leaks
Mixture preparation – injection:
1 Injection system
1.1 Overview of fitting locations – injection system
2 Air filter
2.1 Assembly overview – air filter housing
2.2 Removing and installing air filter housing
2.3 Removing and installing air guide on lock carrier
Intake manifold:
3.1 Assembly overview – intake manifold
3.2 Removing and installing intake manifold
3.3 Removing and installing throttle valve module GX3
3.4 Cleaning throttle valve module GX3
Injectors:
4.1 Assembly overview – fuel rail with injectors
4.2 Removing and installing fuel rail
4.3 Removing and installing injectors
4.4 Cleaning injectors
Senders and sensors:
5.1 Removing and installing intake manifold sender GX9
5.2 Removing and installing fuel pressure sender G247
5.3 Checking fuel pressure sender G247
5.4 Removing and installing exhaust gas pressure sensor 1 G450
5.5 Removing and installing air mass measurement module GX35
High-pressure pump:
6.1 Assembly overview – high-pressure pump
6.2 Removing and installing high-pressure pump
6.3 Removing and installing high-pressure pipe
Lambda probe:
7.1 Assembly overview – Lambda probe
7.2 Removing and installing Lambda probe
Engine control unit:
8.1 Removing and installing engine (motor) control unit J623
Exhaust system:
1 Exhaust pipes and silencers
1.1 Assembly overview – silencers
1.2 Removing and installing silencer
1.3 Separating exhaust pipes from silencers
1.4 Aligning exhaust system free of stress
1.5 Checking exhaust system for leaks
1.6 Installation position of clamp
1.7 Assembly overview – front exhaust pipe
1.8 Removing and installing bracket for front exhaust pipe
Emission control:
2.1 Assembly overview – emission control
2.2 Removing and installing catalytic converter
2.3 Removing and installing particulate filter
2.4 Removing and installing exhaust flap control unit J883
Ignition system:
1 Ignition system
1.1 Assembly overview – ignition system
1.2 Removing and installing ignition coils with output stage
1.3 Removing and installing knock sensor 1 G61
1.4 Removing and installing engine speed sender G28
1.5 Removing and installing inlet camshaft position sender G1002
1.6 Removing and installing exhaust camshaft position sender G1003
Removed 5-speed manual gearbox 0AH
Technical data:
1 Safety information
2 Identification
3 Technical data
3.1 Allocation gearbox – engine
3.2 Calculation of gear ratios
3.3 Capacities
4 Overview – power transmission
5 Electrical components
6 Repair notes
6.1 General repair instructions
Clutch:
1 Clutch mechanism
1.1 Assembly overview – clutch release mechanism
1.2 Repairing clutch release mechanism
2 Clutch
2.1 Assembly overview – clutch
2.2 Removing and installing clutch
Controls, housing:
1 Selector mechanism
2 Removing and installing gearbox
3 Transporting gearbox
4 Gear oil
5 Dismantling and assembling gearbox
5.1 Schematic overview – gearbox
5.2 Assembly overview – gearbox
5.3 Assembly overview – cover for gearbox housing and 5th gear
5.4 Assembly overview – clutch housing
5.5 Assembly overview – shafts, differential, selector mechanism
5.6 Assembly overview – selector forks
5.7 Repairing selector forks
5.8 Dismantling and assembling gearbox
6 Gearbox housing, clutch housing
6.1 Assembly overview – gearbox housing and clutch housing
6.2 Repairing gearbox housing
Gears, shafts:
1 Input shaft
1.1 Assembly overview – input shaft
1.2 Dismantling and assembling input shaft
1.3 Renewing input shaft seal
2 Output shaft
2.1 Assembly overview – output shaft
2.2 Dismantling and assembling output shaft
Final drive – differential:
1 Oil seals
1.1 Overview of fitting locations – seals
2 Differential
2.1 Assembly overview – differential
2.2 Dismantling and assembling differential
2.3 Adjusting differential
Removed 6-speed manual gearbox 0AJ
Technical data:
1 Safety information
2 Identification
3 Technical data
3.1 Capacities
4 Overview – power transmission
5 Electrical components
6 Repair notes
6.1 General repair instructions
Clutch:
1 Clutch mechanism
1.1 Assembly overview – clutch release mechanism
1.2 Repairing clutch release mechanism
2 Clutch
2.1 Assembly overview – clutch
2.2 Removing and installing clutch
Controls, housing:
1 Selector mechanism
2 Removing and installing gearbox
3 Transporting gearbox
4 Gear oil
5 Securing to engine and gearbox support
6 Dismantling and assembling gearbox
6.1 Overview – gearbox
6.2 Assembly overview – gearbox
6.3 Assembly overview – gearbox housing cover
6.4 Assembly overview – clutch housing
6.5 Assembly overview – shafts, differential, selector mechanism
6.6 Assembly overview – selector forks
6.7 Repairing selector forks
6.8 Dismantling and assembling gearbox
7 Gearbox housing, clutch housing
7.1 Assembly overview – gearbox housing and clutch housing
7.2 Assembly overview – gearbox housing cover
7.3 Repairing gearbox housing
7.4 Repairing gearbox housing cover
Gears, shafts:
1 Input shaft
1.1 Assembly overview – input shaft
1.2 Dismantling and assembling input shaft
1.3 Renewing input shaft seal
2 Output shaft
2.1 Assembly overview – output shaft
2.2 Dismantling and assembling output shaft
Final drive – differential:
1 Seals
1.1 Overview of fitting locations – seals
2 Differential
2.1 Assembly overview – differential
2.2 Dismantling and assembling differential
2.3 Adjusting differential
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