Car engine number Remove the hose from the activated carbon absorber at the hose clamp "arrow". The engine letter designation and number are located on the "arrow" sticker attached to the timing...
Specifications of the 1.4 litre/110 kW petrol engine (BWK) Engine letter designation BWK Made with 10.07 Toxicity indicators, OG EU4 Working volume, cm/cube 1390 Power, kW at rpm 110/5800 Torque, Nm at rpm 240/1750-4000 Inner diameter of...
Removal the engine Disconnect the vacuum hose "arrow". Lift the engine casing at points "1" and remove the casing by moving it forward in the -direction of the arrow-. Unscrew the heat shield above...
Engine installation Installation is carried out in reverse order, taking into account the following. Caution: When carrying out any installation work, particularly in the engine compartment due to...
Disassembling the engine Instructions. If, during engine repair, large quantities of metal shavings and dust are found in the engine oil - the source of which is increased wear, for example, due to damage...
Engine assembly Poly V-belt reeving Caution: Before installing the poly V-belt, check that all components driven by it are securely fastened (generator, air conditioning compressor). When...
Removal and installation of lubrication system elements Instructions: If large quantities of metal shavings are found in the engine during repair, this may be due to a faulty connecting rod bearing. To avoid subsequent damage, the...
Removal and installation of cooling system components Caution: When carrying out any installation work, particularly in the engine compartment due to the tight layout, the following must be taken into account. Lines of all types (for...
Draining and filling the coolant Drain CAUTION: When opening the expansion tank, hot steam may escape. Remove the crankcase protection. Release the spring clamp and remove the coolant hose "2". Ignore position...
Removal and installation the radiator and radiator fan V7 Depending on the vehicle configuration, remove the sound insulation or underride guard. Remove the front right and left mudguard. Remove the holder "1" by unscrewing the mounting...
Removal and installation the cooling system pump Drain the coolant. Disconnect the fuel supply line "1" and the line to the activated carbon canister "2". Press the release buttons to do this. Loosen the hose clamp "1" in the...
Fuel tank device 1 - Cover, replace if damaged 2 - Mounting bolt 3 - Ground connection, check the reliability of the fastening 4 - Ventilation line to the absorber, check the reliability of the...
Removal and installation of the fuel tank Removal With the ignition off, disconnect the battery ground wire. Unscrew the fuel filler cap assembly mounting bolt and remove it. Pump out the fuel from the tank and clean the...
Removal and installation of power supply system components Instructions: Hose connections are secured with spring and clamp clamps. Clamp clamps should always be replaced with spring clamps. Fuel hoses may only be secured to the engine...
Turbocharger device Instructions: All hose connections must be secured with standard clamps corresponding to the model year. Hoses and hose nipples of the air supercharging system must be cleaned of...
Removal and installation a turbocharger Disconnect the battery. Disconnect the vacuum hose "arrow". Lift the engine casing at points "1" and remove the casing by moving it forward in the -direction of the arrow-....
Removal and installation the turbocharger vacuum block Unlock the vacuum line clamp on the vacuum receiver "arrow" and disconnect it, Raise the engine casing at points "1" and remove the casing by moving it forward in the -direction...
Compressor device 1 - Housing with noise-insulating screen of noise damper 2 - Noise insulation of intake air 3 - Air intake hose, secure with spring clamps 4 - 7 Nm, self-tapping screw. Tighten...
Removal and installation the compressor Disconnect the battery. Open and close the expansion tank cap again to relieve pressure in the cooling system. Drain the coolant. Disconnect the vacuum hose "arrow". Lift the...
Turbocharging system Instructions: All hose connections must be secured with standard clamps corresponding to the model year. Hoses and hose nipples of the air boost system must be cleaned of oil and...
Removal and installation the intercooler Depending on the vehicle configuration, remove the sound insulation or underride guard. Remove the front right and left mudguard. Remove the holder "1" by unscrewing the mounting...
Fuel injection system The engine control unit "J623" is equipped with a self-diagnosis function. Before repairs, as well as for troubleshooting, the fault memory should be interrogated first. It is...
Checking the operation of the intake manifold flap After installing the new lower part of the intake manifold, remove the fastening bracket "arrow" of the actuator element of the vacuum drive. Connect the hand vacuum pump -VAS...
High pressure fuel pump CAUTION: The injection system is divided into a high-pressure area (up to max 120 bar) and the low area (about 6 bar) pressure. Before opening the high pressure area (for example,...
Removal and installation the high pressure pump Remove the air filter. Disconnect the fuel supply line "arrow". Disconnect the connector and the "arrow" fuel supply line from the high-pressure pump. Remove guide "2" and remove...
Removal and installation engine control unit J623 Before replacing the engine control unit, connect the tester -VAS 5051 B- and perform the Guided Function "Replacing the engine control unit". Switch off the ignition. Remove the...
Theft-protected engine control unit Before replacing the engine control unit, connect the tester -VAS 5051B- and perform the Guided Function "Replacing the engine control unit". Switch off the ignition. Remove the...
Catalyst and exhaust system attachments Instructions: After installation work on the exhaust system, check that it is installed without tension and that the distance between the exhaust system elements and the body is...
Silencer with add-on elements 1 - Exhaust pipe with middle and rear mufflers. At the factory it is installed with the main muffler as one piece, in case of repair it is replaced separately 2 - 20 Nm 3 -...
Removal and installation the exhaust pipe Depending on the vehicle configuration, remove the sound insulation or underride guard. Remove the lambda probe after the catalytic converter "G130" "1". Unscrew the exhaust pipe...
Ignition system repair General instructions for the ignition system The engine control unit "J623" has a self-diagnosis function. A voltage of at least 11.5 V is required to maintain the faultless...