4-Cyl. injection engine (1.6 l)

Chapter overview

• Technical data
  1
• 1 \--- Change history ---
  1
• 2 Safety instructions
  2
• 2.1 Safety measures regarding work on the fuel supply
  2
• 2.2 Safety measures for working on the injection and ignition system
  2
• 3 Repair instructions
  4
• 3.1 Cleanliness rules
  4
• 4 Technical Data
  5
• 4.1 Engine number
  5
• 4.2 Engine characteristics
  5
• Removing and installing engine
  7
• 1 Engine - remove and install
  7
• 1.1 Engine - removal
  7
• 1.2 Engine - fasten to assembly stand
  17
• 1.3 Engine - installation
  18
• 2 Power-drive unit supports
  21
• 2.1 Power unit brackets - assembly overview
  21
• 2.2 Drive train mountings - alignment
  23
• Crankshaft group
  26
• 1 Cylinder block (pulley side)
  26
• 1.1 Poly-V belt drive (elastic) - assembly overview
  27
• 1.2 Cylinder block (pulley side) - assembly overview
  29
• 1.3 Seal lid - replace
  31
• 1.4 Poly-V belt (elastic) - remove and install
  31
• 1.5 Crankshaft pulley - removal and installation
  36
• 1.6 Crankshaft seal (pulley side) - replace
  36
• 2 Cylinder block, gearbox side
  40
• 2.1 Crankshaft and flywheel flanges - assembly overview
  40
• 2.2 Flywheel - remove and install
  42
• 2.3 Crankshaft flange (flywheel side) with Engine speed sensor G28 rotor - replace
  43
• 3 Crankshaft
  55
• 3.1 Crankshaft - assembly overview
  55
• 3.2 Identifying engine bearing shells
  56
• 3.3 Colour codes
  58
• 3.4 Crankshaft - dimensions
  58
• 4 Pistons and conrods
  59
• 4.1 Pistons and conrods - assembly overview
  59
• 4.2 Pistons, rings, and cylinders - check
  61
• 4.3 Piston and cylinder - dimensions
  64
• Cylinder head, valve gear
  65
• 1 Engine cylinder head
  65
• 1.1 Engine cylinder head - assembly overview
  65
• 1.2 Cylinder head - remove and install
  68
• 1.3 Compression - check
  73
• 2 Toothed belt drive
  76
• 2.1 Toothed belt semi-automatic tensioning pulley - check
  76
• 2.2 Toothed belt - remove and install, adjust
  77
• 3 Camshaft
  84
• 3.1 Camshaft - assembly overview
  84
• 3.2 Camshaft - check axial clearance
  87
• 3.3 Camshaft seal - replace
  89
• 3.4 Camshaft and cylinder head cover - remove and install
  94
• 3.5 Valve stem sealant - replace
  99
• 4 Inlet and exhaust valves
  102
• 4.1 Valve seat - trim
  102
• 4.2 Valve guides - check
  104
• Lubrication
  106
• 1 Lubrication system components
  106
• 1.1 Lubricating system components - assembly overview
  106
• 1.2 Engine oil
  109
• 1.3 Crankcase - remove and install
  110
• 1.4 Oil pump - remove and install
  113
• 2 Oil filter / Oil pressure switch F1
  118
• 2.1 Oil pressure switch F1 - remove and install
  118
• 2.2 Oil pressure and Oil pressure switch F1 - check
  118
• 2.3 Oil filter - replace
  120
• Cooling
  123
• 1 Cooling system components
  123
• 1.1 Hose connection diagram for cooling system
  123
• 1.2 Cooling system - drainage and replenishment
  124
• 1.3 Cooling system - check air-tightness
  133
• 1.4 Coolant tank flap - check safety valve
  135
• 2 Water pump / coolant adjustment
  137
• 2.1 Water pump - assembly overview
  137
• 2.2 Thermostat valve - assembly overview
  138
• 2.3 Water pump - remove and install
  140
• 3 Radiator / Radiator fan
  143
• 3.1 Radiator / Radiator fan - assembly overview
  143
• 3.2 Radiator - remove and install
  145
• 3.3 Cowling with Radiator fan V7 - remove and install
  146
• 3.4 Radiator fan V7 - remove and install
  147
• Fuel supply system
  148
• 1 Fuel supply system components
  148
• 1.1 Fuel tank components with accessories and fuel filter - assembly overview
  148
• 1.2 Cold start system components - remove and install
  154
• 1.3 Fuel tank - remove and install
  155
• 1.4 Fuel reservoir (EU5) - remove and install
  157
• 2 Fuel supply unit / fuel level sensor
  161
• 2.1 Fuel pump (pre-supply pump) G6 - remove and install
  161
• 2.2 Fuel gauge sensor G - remove and install
  164
• 3 Activated charcoal filter system
  165
• 3.1 Operation
  165
• 3.2 Activated charcoal filter system - assembly overview
  165
• 3.3 Magnetic valve 1 for activated charcoal filter N80 - remove and install
  166
• 3.4 Fuel tank ventilation - check
  167
• 4 Engine power electronic adjustment (electronic accelerator)
  169
• 4.1 Engine power electronic adjustment (electronic accelerator) - assembly overview
  169
• 4.2 Electronic accelerator system operation
  169
• 5 Fuel pump (pre-supply pump) G6
  171
• 5.1 Voltage supply of the Fuel pump (pre-supply pump) G6 - check
  173
• 5.2 Fuel supply system output - check
  175
• 5.3 Current consumption - check
  180
• 5.4 Fuel pump (pre-supply pump) G6 retention valve - check
  180
• Mixture preparation - injection
  182
• 1 Injection system
  182
• 1.1 General instructions regarding the injection system
  182
• 1.2 Injection system - assembly overview
  182
• 1.3 Injection components - assembly overview
  184
• 1.4 Technical Data
  187
• 2 Injection valves
  188
• 2.1 Fuel rail with injectors - assembly overview
  188
• 2.2 Injection valves - check
  188
• 2.3 Injection valves - clean
  193
• 3 Air cleaner
  195
• 3.1 Air filter - assembly overview
  195
• 3.2 Air filter - remove and install
  196
• 4 Intake manifold
  198
• 4.1 Intake manifold - assembly overview
  198
• 4.2 Throttle valve control unit J338 - clean
  199
• 5 Component checks
  201
• 5.1 Supply system pressure, fuel pressure gauge and residual pressure - check
  201
• 6 READINESS code
  207
• 6.1 Creating and Interpreting the READINESS code
  207
• 7 Engine control unit J623
  208
• 7.1 Engine control unit J623 - remove and install
  208
• 7.2 Adjust components
  209
• 7.3 Check the event memory in the Engine control unit J623 and delete it
  210
• Exhaust system
  212
• 1 Rear muffler
  212
• 1.1 Rear muffler - assembly overview
  212
• 1.2 Silencer/exhaust pipes - detach
  212
• 1.3 Exhaust system - tension free alignment
  213
• 1.4 Pipe clamp installation position
  214
• Glow plug system
  218
• 1 Ignition system
  218
• 1.1 General instructions regarding the ignition system
  218
• 1.2 Ignition system - assembly overview
  218
• 1.3 Spark plugs Q - test data
  220