Engines CPTA, CZCA, CZEA (1.4L 4v EA211), service e-manual

CONTENTS Technical data Safety information Safety regulations for working on fuel supply Safety measures when working on vehicles with a start/stop system Safety precautions when using testers and measuring instruments during a road test Safety precautions when working on the cooling system Safety precautions when working on ignition system Identification Engine number/engine data Repair instructions Rules for cleanliness Foreign objects in engine Contact corrosion Routing and attachment of lines Fitting radiator and condensers Removing and installing engine Removing engine Separating engine and gearbox Securing engine on engine and gearbox support Installing engine Assembly mountings Removing and installing engine mounting Removing and installing gearbox mounting Removing and installing pendulum support Supporting engine in installation position Crankshaft group Cylinder block (pulley end) Assembly overview - poly V-belt drive Assembly overview - sealing flange, belt pulley end Removing and installing poly-V belt Removing and installing tensioner for poly V-belt Removing and installing vibration damper Removing and installing engine support Renewing crankshaft oil seal - belt pulley end Removing and installing sealing flange on pulley end Cylinder block, gearbox end Removing and installing flywheel Removing and installing sealing flange on gearbox side Crankshaft Crankshaft dimensions Renewing needle bearing in crankshaft Measuring axial clearance of crankshaft Assembly overview - pistons and conrods Separating new conrod Removing and installing pistons Removing and installing oil spray jets Checking pistons and cylinder bores Checking radial clearance of conrods Setting piston to TDC position Cylinder head, valve gear Assembly overview - camshaft housing Removing and installing cylinder head Removing and installing camshaft housing Checking compression Toothed belt drive Assembly overview - toothed belt cover Assembly overview - toothed belt Removing and installing toothed belt guard Preassembling and installing valve timing tool Checking valve timing Adjusting valve timing Removing toothed belt from camshaft Removing and installing toothed belt Valve gear Assembly overview - valve gear Removing and installing camshaft oil seal Removing and installing camshaft adjuster Removing and installing toothed belt pulley Removing and installing camshaft control valve 1 N205 Removing and installing exhaust camshaft control valve 1 N318 Removing and installing valve stem seals Removing and installing cam actuators Inlet and exhaust valves Checking valve guides Checking valves Valve dimensions Lubrication Sump, oil pump Engine oil Removing and installing lower part of sump Removing and installing upper part of sump Removing and installing oil pump Removing and installing oil level and oil temperature sender G266 Engine oil cooler Assembly overview - engine oil cooler Removing and installing engine oil cooler Crankcase ventilation Assembly overview - crankcase breather system Removing and installing oil separator Oil filter, oil pressure switch Assembly overview - oil filter/oil pressure switch Removing and installing oil pressure switch F1 Removing and installing oil pressure switch for reduced oil pressure F378 Checking oil pressure Removing and installing oil pressure regulating valve N428 Cooling Cooling system/coolant Connection diagram - coolant hoses Checking cooling system for leaks Draining and adding coolant Coolant pump, regulation of cooling system Assembly overview - coolant pump, thermostat Assembly overview - electric coolant pump Assembly overview - coolant temperature sender Removing and installing electric coolant pump Removing and installing coolant pump Removing and installing thermostat Removing and installing toothed belt pulley for coolant pump Removing and installing coolant temperature sender G62 Removing and installing radiator outlet coolant temperature sender G83 Coolant pipes Removing and installing coolant pipes Radiator, radiator fan Removing and installing radiator Removing and installing water radiator for charge air cooling circuit Removing and installing radiator cowl with radiator fan Removing and installing radiator fan V7 Turbocharging/supercharging Exhaust turbocharger Removing and installing turbocharger Removing and installing charge pressure positioner V465 Removing and installing connection for turbocharger Charge air system Removing and installing charge air cooler Removing and installing charge pressure sender GX26 Checking charge air system for leaks Removing and installing air intake pipe Mixture preparation – injection Injection system Injectors Assembly overview - fuel rail with injectors Removing and installing fuel rail Removing and installing injectors Cleaning injectors Air filter Removing and installing air filter housing Removing and installing resonator for intake air Intake manifold Removing and installing intake manifold Removing and installing throttle valve module GX3 Cleaning throttle valve module GX3 Senders and sensors Removing and installing fuel pressure sender G247 Checking fuel pressure sender G247 Removing and installing intake manifold sender GX9 Removing and installing engine (motor) control unit J623 Removing and installing engine (motor) control unit J623 with protective housing Removing and installing high-pressure pump Removing and installing high-pressure pipe Lambda probe Removing and installing Lambda probe Exhaust system Separating exhaust pipes from silencers Removing and installing silencer Aligning exhaust system free of stress Check exhaust system for leaks Exhaust gas cleaning Assembly overview - emission control Removing and installing catalytic converter Ignition system Removing and installing ignition coils with output stage Removing and installing knock sensor 1 G61 Removing and installing Hall sender Removing and installing engine speed sender G28

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