4-Cyl. injection engine (1.6 ltr., 4 valve)

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Technical data
  1
• 1.2 Engine number
  1
• 1.3 Engine data
  1
• Removing and installing engine
  3
• 1 Removing and installing engine
  3
• 1.1 Removing and installing engine
  3
• 1.2 Notes on removing
  4
• 1.3 Securing engine to assembly stand
  7
• 1.4 Notes on installing
  7
• 1.5 Tightening torques
  8
• 1.6 Assembly mountings
  9
• 1.7 Additional information and removal instructions for vehicles with air conditioner
  10
• Crankshaft group
  11
• 1 Dismantling and assembling engine
  11
• 1.1 Dismantling and assembling engine
  11
• 1.2 Removing and installing ribbed belt
  21
• 2 Dismantling and assembling cylinder block, crankshaft and flywheel
  23
• 2.1 Dismantling and assembling cylinder block, crankshaft and flywheel
  23
• 2.2 Crankshaft dimensions
  26
• 2.3 Renewing crankshaft oil seal -belt pulley end-
  26
• 2.4 Renewing crankshaft sealing flange -flywheel end-
  28
• 3 Dismantling and assembling pistons and conrods
  37
• 3.1 Dismantling and assembling pistons and conrods
  37
• 3.2 Piston and cylinder dimensions
  43
• Cylinder head, Valve gear
  44
• 1 Removing and installing cylinder head
  44
• 1.1 Removing and installing cylinder head
  44
• 1.2 Checking valve timing
  49
• 1.3 Checking semi-automatic toothed belt tensioning roller
  52
• 1.4 Removing, installing and tensioning toothed belts
  56
• 1.5 Removing and installing camshaft housing
  63
• 1.6 Removing and installing cylinder head
  66
• 1.7 Checking compression pressures
  69
• 2 Servicing valve gear
  71
• 2.1 Servicing valve gear
  71
• 2.2 Reworking valve seats
  80
• 2.3 Removing and installing camshaft adjuster and exhaust camshaft sprocket
  82
• 2.4 Renewing camshaft oil seals
  90
• 2.5 Checking valve guides
  93
• 2.6 Renewing valve guides
  94
• 2.7 Renewing valve stem seals
  95
• Lubrication
  98
• 1 Removing and installing parts of the lubrication system
  98
• 1.1 Removing and installing parts of the lubrication system
  98
• 1.2 Removing and installing oil sump
  105
• 1.3 Removing and installing oil pump
  107
• 1.4 Checking oil pressure and oil pressure switch
  110
• Cooling system
  112
• 1 Removing and installing parts of cooling system
  112
• 1.1 Removing and installing parts of cooling system
  112
• 1.2 Parts of cooling system body side
  113
• 1.3 Parts of cooling system engine side
  116
• 1.4 Coolant hose connection diagram
  121
• 1.5 Draining and filling cooling system
  122
• 1.6 Removing and installing radiator
  124
• 1.7 Removing and installing coolant pump
  126
• Fuel supply system
  128
• 1 Removing and installing parts of fuel supply system
  128
• 1.1 Removing and installing parts of fuel supply system
  128
• 1.2 Removing and installing fuel tank with its attachments and fuel filter
  129
• 1.3 Safety precautions when working on the fuel supply system
  133
• 1.4 Rules for cleanliness
  134
• 1.5 Removing and installing fuel delivery unit
  134
• 1.6 Removing and installing fuel tank
  135
• 1.7 Crash fuel shut-off
  137
• 1.8 Checking fuel pump
  138
• 2 Electronic power control (EPC)
  144
• 2.1 Electronic power control (EPC)
  144
• 2.2 Servicing parts of electronic power control (EPC)
  144
• 3 Activated charcoal filter system
  145
• 3.1 Activated charcoal filter system
  145
• 3.2 Servicing parts of the activated charcoal filter system
  145
• 3.3 Checking fuel tank breather
  147
• Mixture preparation, Injection
  149
• 1 Servicing injection system
  149
• 1.1 Servicing injection system
  149
• 1.2 Fitting locations overview
  149
• 1.3 General notes on injection
  155
• 1.4 Removing and installing parts of the injection system
  156
• 1.5 Dismantling and assembling intake manifold
  164
• 1.6 Dismantling and assembling fuel rail with injectors
  167
• 1.7 Dismantling and assembling air cleaner
  170
• 1.8 Safety precautions
  173
• 1.9 Rules for cleanliness
  174
• 1.10 Technical data
  174
• 2 Checking components
  175
• 2.1 Checking components
  175
• 2.2 Checking injectors
  175
• 2.3 Checking fuel pressure regulator and holding pressure
  178
• 2.4 Adapting components
  182
• Exhaust system
  183
• 1 Removing and installing parts of exhaust system
  183
• 1.1 Removing and installing parts of exhaust system
  183
• 1.2 Exhaust manifold, front exhaust pipe and catalyst with attachments
  183
• Ignition system
  190
• 1 Servicing ignition system
  190
• 1.1 Servicing ignition system
  190
• 1.2 General notes on ignition system
  190
• 1.3 Removing and installing parts of the ignition system
  191
• 1.4 Safety precautions
  193
• 1.5 Test data, spark plugs
  194