1.4L/1.6L 4-cylinder 4-valve gasoline engine CKA/CPD/CSR/DAH

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Engine number
  1
• 1.2 Engine data
  1
• 2 Safety caution
  3
• 2.1 Precautions for fuel supply system working
  3
• 2.2 Safety measures when using testing and measuring devices in trail running
  3
• 2.3 Safety measure when the ignition system is in working
  4
• 2.4 Safety measure when the cooling system is working
  4
• 3 Maintenance instruction
  6
• 3.1 Clean requirements
  6
• 3.2 Foreign objects in engine
  6
• 3.3 Contact corrosion
  6
• 3.4 Pipe arrangement and fixing
  6
• 3.5 Installation of radiator and condenser
  6
• Disassembly and installation of engine
  8
• 1.1 Remove the engine
  9
• 1.2 Disengage the engine and 5-speed manual gearbox NJS/NJV/QNM/QAA
  18
• 1.3 Remove engine and 6-speed automatic gearbox NMT/NKN/PRZ/PLS
  19
• 1.4 Fix the engine on assembly bracket
  20
• 1.5 Installation of engine
  22
• 2.1 Remove the engine
  28
• 2.2 Disengage the engine and 5-speed manual gearbox NYZ
  38
• 2.3 Remove engine and 6-speed automatic gearbox NKN
  39
• 2.4 Fix the engine on assembly bracket
  40
• 2.5 Installation of engine
  42
• 3 Disassembly and installation of engine (applicable for New Touran)
  48
• 3.1 Remove the engine
  49
• 3.2 Disengage the engine and 5-speed manual gearbox PQN
  58
• 3.3 Fix the engine on assembly bracket
  58
• 3.4 Installation of engine
  60
• 4 Unit support (applicable for New Santana, New Polo and Gran Santana)
  65
• 4.3 Disassembly and installation of engine support
  68
• 4.4 Disassembly and installation of engine strut member
  69
• 4.5 Disassembly and installation of gearbox base
  72
• 4.6 Adjust engine support
  75
• 5.1 Unit support-assembly overview (models equipped with 5-speed automatic gearbox NYZ)
  77
• 5.2 Unit support-assembly overview (models equipped with 6-speed automatic gearbox NKN)
  79
• 5.3 Disassembly and installation of engine support
  81
• 5.4 Disassembly and installation of engine supporting device
  82
• 5.5 Disassembly and installation of gearbox base
  85
• 5.6 Adjust engine support
  87
• 6 Unit support (applicable for New Touran)
  90
• 6.1 Unit support-assembly overview
  90
• 6.2 Disassembly and installation of engine support
  92
• 6.3 Disassembly and installation of engine supporting device
  93
• 6.4 Disassembly and installation of gearbox base
  96
• 6.5 Adjust engine support
  98
• Crank connecting rod mechanism
  102
• 1 Disassembly and assembly of engine
  102
• 1.1 Belt driven-assembly overview
  102
• 1.2 Sealing flange/engine pump at pulley side- assembly overview
  104
• 1.3 Disassembly and installation of V-ribbed belt
  106
• 1.4 Disassembly and installation of tensioner
  107
• 1.6 Disassembly and installation of tensioner bracket (Applicable for New Polo)
  111
• 1.8 Disassembly and installation of tensioner bracket (Applicable for New Polo)
  117
• 1.9 Disassembly and installation of crankshaft pulley
  120
• 1.10 Replace the sealing ring at the pulley belt’s side
  124
• 2 Cylinder block on gearbox side
  127
• 2.1 Models equipped with 5-speed manual gearbox NJS/NJV/QNM/QAA
  127
• 2.3 Disassembly and installation of sealing flange at gearbox side
  134
• 3 Crankshaft
  142
• 3.1 Crankshaft dimension
  142
• 3.2 Measure the crankshaft clearance
  142
• 4 Piston and connecting rod
  143
• 4.1 Piston and connecting rod-assembly overview
  143
• 4.2 Disassembly and installation of piston
  145
• 4.3 Check the piston
  147
• 4.4 Check the cylinder inner bore
  148
• 4.5 Piston and cylinder dimension
  148
• Cylinder hood,valve mechanism
  149
• 1 Belt driven
  149
• 1.1 Belt protective cover-assembly overview
  149
• 1.2 Toothed belt -assembly overview
  150
• 1.3 Release the timing toothed belt from the camshaft
  152
• 1.4 Disassembly and installation of timing toothed belt
  162
• 2 Cylinder hood
  173
• 2.1 Cylinder hood-Assembly Overview
  173
• 2.2 Disassembly and installation of cylinder hood
  174
• 2.3 Check the compression pressure of cylinder
  179
• 3 Valve mechanism
  182
• 3.1 Valve mechanism - assembly overview
  182
• 3.2 Valve-Assembly Overview
  184
• 3.4 Check the axial clearance of the camshaft
  185
• 3.5 Disassembly and installation of camshaft seal ring
  186
• 3.6 Disassembly and installation camshaft box
  191
• 3.7 Disassembly and installation of valve stem oil seal
  195
• 4 Intake valve and exhaust valve leakage
  199
• 4.1 Check valve guide pipe
  199
• 4.2 Check the valve
  199
• 4.3 Valve dimension
  199
• Lubrication system
  200
• 1 Components of lubrication system
  200
• 1.1 Engine oil
  200
• 1.2 Oil sump and oil pump - assembly overview
  202
• 1.3 Disassembly and installation of oil sump
  204
• 1.4 Disassembly and installation of sealing flange/engine pump at pulley side
  207
• 2 Crankshaft case exhaust
  211
• 2.1 Disassembly and installation of oil wiper
  212
• 3 Oil filter/oil pressure switch
  214
• 3.1 Oil filter/oil pressure switch-assembly overview
  214
• 3.2 Disassembly and installation of oil pressure switch
  214
• 3.3 Check oil pressure and oil pressure switch
  215
• 3.4 Check the engine oil level
  217
• Cooling System
  219
• 1 The components of cooling system
  219
• 1.3 Coolant hose connection diagram (Applicable for New Polo)
  222
• 1.4 Coolant hose connection diagram (Applicable for New Touran)
  223
• 1.5 Discharge and add coolant
  224
• 1.6 Check the tightness of the cooling system
  228
• 2 Coolant pump / coolant adjusting device
  231
• 2.1 Coolant pump / coolant adjusting device (Applicable for New Santana and Gran Santana)
  231
• 2.5 Disassemble and install coolant pump toothed belt pulley
  240
• 2.10 Disassemble and install coolant temperature sensor G62
  247
• 3 Coolant pipe
  249
• 3.1 Coolant pipe - assembly overview
  249
• 4 (Applicable for New Santana, New Polo and Gran Santana)
  251
• 4.1 Assembly Overview
  251
• 4.2 Radiator fan
  252
• 4.4 Disassembly and installation of radiator (Applicable for New Polo)
  255
• 4.5 Dismantle and install radiator fan cover(applicable for New Santana and Gran Santana)
  258
• 4.6 Disassembly and installation of radiator fan cover(Applicable for New Polo)
  258
• 4.7 Disassemble and install radiator fan V7
  259
• 5.2 Radiator fan - Assembly Overview (applicable for New Touran)
  262
• 5.3 Radiator fan- Assembly Overview
  264
• 5.5 Disassembly and installation of radiator (applicable for New Touran)
  266
• 5.6 Disassembly and installation of radiator fan cover
  269
• 5.7 Disassemble and install radiator fan V7 and radiator fan control unit J293
  270
• Fuel supply system
  271
• 1 Components of the fuel supply equipment
  271
• 1.1 The safety cautions taken to operate fuel supply equipment
  271
• 1.2 Clean requirements
  272
• 1.4 Fuel tank and installation parts - assembly overview (Applicable for New Polo)
  274
• 1.5 Fuel tank and fitting parts - assembly overview (applicable for New Touran)
  276
• 1.6 Exhaust the fuel tank
  278
• 1.8 Disassemble and install fuel pump(applicable for New Touran )
  283
• 1.10 Disassembly and installation of fuel stock sensor G (applicable for New Polo)
  287
• 1.11 Disassembly and installation of fuel stock sensor G (applicable for New Touran)
  288
• 1.12 Dismantle and install fuel tank(applicable for New Santana and Gran Santana)
  289
• 1.14 Disassembly and installation of fuel tank(Applicable for New Polo)
  295
• 1.15 Disassemble and install the fuel tank (applicable for New Touran)
  298
• 1.18 Conduct electrical check to the fuel pump
  304
• 1.19 Fuel cut-off device on collision
  306
• 1.20 Fuel filter and fitting parts - assembly overview
  306
• 1.21 Disassembly and installation of fuel filter
  307
• 1.22 Inspect fuel delivery of the fuel pump
  308
• 1.23 Check the fuel pump(applicable for New Polo, New Touran)
  313
• 2 Electronic power control (EPC)
  321
• 2.1 Electronic power control function
  321
• 2.3 Accelerator pedal - assembly overview (applicable for New Touran)
  323
• 3 Activated carbon canister (applicable for New Santana and Gran Santana)
  326
• 3.1 Functions
  326
• 3.2 Activated carbon canister-Assembly overview
  326
• 3.3 Disassembly and installation of the activated carbon canister
  327
• 3.4 Inspect the fuel tank exhaust
  328
• 4.1 Functions
  332
• 4.2 Activated carbon canister-Assembly overview
  332
• 4.3 Disassembly and installation of the activated carbon canister
  333
• 4.4 Inspect the fuel tank’s oil level
  334
• 5 Activated carbon canister (applicable for New Polo)
  337
• 5.1 Functions
  337
• 5.2 Activated carbon canister-Assembly overview
  337
• 5.3 Disassembly and installation of the activated carbon canister
  338
• 5.4 Inspect the fuel tank exhaust
  339
• 6 Activated charcoal canister (applicable for New Touran)
  344
• 6.1 Function
  344
• 6.2 Activated carbon canister-Assembly overview
  344
• 6.3 Disassembly and installation of the activated carbon canister
  345
• 6.4 Inspect the fuel tank exhaust
  346
• Mixed gas preparation, injection system
  349
• 1 Injection system
  349
• 1.1 Installation position:
  349
• 2 (Applicable for New Santana, New Polo and Gran Santana)
  353
• 2.1 Air filter-Assembly overview
  353
• 2.2 Dismantle and install the air filter housing
  354
• 3.1 Air filter
  355
• 3.2 Dismantle and install the air filter housing
  356
• 4 Intake manifold
  358
• 4.1 Intake manifold - assembly overview
  358
• 4.4 Disassemble and install the throttle control unit J338
  365
• 4.5 Clean throttle control unit J338
  367
• 4.6 Technical data
  367
• 5 Fuel injector
  368
• 5.1 Fuel distributor with fuel injectors - assembly overview
  368
• 5.2 Disassemble and install the fuel distributor with fuel injectors
  369
• 5.3 Check the tightness and injection volume of the fuel injectors
  370
• 5.4 Check the fuel pressure regulator and holding pressure
  373
• 6 Sensor
  377
• 6.1 Disassemble and install intake air temperature sensor G42 / intake pipe pressure sensor G71
  377
• 7 Oxygen sensor
  378
• 7.2 Oxygen sensor - assembly overview (applicable for New Touran)
  379
• 8 Motronic control unit
  385
• Exhaust system
  394
• 1 Exhaust system components (applicable for New Santana, New Polo and Gran Santana)
  394
• 1.1 Exhaust catalytic cleaner and fitting parts - assembly overview
  394
• 1.2 Install and disassemble the front exhaust pipe with exhaust catalytic converter
  396
• 1.4 Muffler and suspension system - assembly overview (applicable for New Polo)
  401
• 1.5 Disassembly and installation of muffler (applicable for New Santana and Gran Santana)
  402
• 1.6 Disassembly and installation of muffler (Applicable for New Polo)
  403
• 1.7 Separate the muffler
  404
• 1.8 Install the exhaust system under the free of stress condition
  406
• 2.1 Exhaust catalytic cleaner and fitting parts - assembly overview
  408
• 2.2 Install and disassemble the front exhaust pipe with exhaust catalytic converter
  410
• 2.3 Muffler and suspension system - assembly overview
  413
• 2.4 Disassembly and installation of muffler
  415
• 2.5 Separate the muffler
  416
• 2.6 Install the exhaust system under the free of stress condition
  417
• 3 The parts of the exhaust system (applicable for New Touran)
  419
• 3.1 Exhaust catalytic cleaner and fitting parts - assembly overview
  419
• 3.2 Install and disassemble the front exhaust pipe with exhaust catalytic converter
  420
• 3.3 Muffler and suspension system - assembly overview
  423
• 3.4 Disassembly and installation of muffler
  425
• 3.5 Separate the muffler
  426
• 3.6 Install the exhaust system under the free of stress condition
  427
• Ignition system
  429
• 1 Ignition device
  429
• 1.1 Ignition device - assembly overview
  429
• 1.2 Test data, spark plug
  430
• 1.3 Install and disassemble ignition coil 1 with power output stage
  431
• 1.4 Install and disassemble knock sensor G61
  432
• 1.5 Dismantle and install the Hall sensor G40
  432
• 1.6 Install and disassemble Engine speed sensor G28
  433