4-cyl. fuel injection engine (1.4 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
  8
• 1.5 Tightening torques
  9
• 1.6 Assembly mountings
  10
• 1.7 Additional information and removal instructions for vehicles with air conditioner
  11
• Crankshaft group
  13
• 1 Dismantling and assembling engine
  13
• 1.1 Dismantling and assembling engine
  13
• 1.2 Removing and installing ribbed belt
  22
• 1.3 Checking valve timing
  23
• 1.4 Removing, installing and tensioning toothed belts
  25
• 1.5 Checking semi-automatic toothed belt tensioning roller
  33
• 2 Removing and installing cylinder block, sealing flange and flywheel/drive plate
  37
• 2.1 Removing and installing cylinder block, sealing flange and flywheel/drive plate
  37
• 2.2 Aluminium cylinder block
  38
• 2.3 Renewing crankshaft oil seal -belt pulley end-
  41
• 2.4 Removing and installing drive plate
  43
• 2.5 Renewing crankshaft sealing flange -flywheel end-
  46
• 2.6 Crankshaft dimensions
  55
• 3 Dismantling and assembling pistons and conrods
  56
• 3.1 Dismantling and assembling pistons and conrods
  56
• 3.2 Piston and cylinder dimensions
  62
• Cylinder head, Valve gear
  63
• 1 Removing and installing cylinder head
  63
• 1.1 Removing and installing cylinder head
  63
• 1.2 Removing and installing camshaft housing
  67
• 1.3 Removing and installing cylinder head
  70
• 1.4 Checking compression pressures
  74
• 2 Servicing valve gear
  76
• 2.1 Servicing valve gear
  76
• 2.2 Reworking valve seats
  84
• 2.3 Replacing camshaft oil seals
  86
• 2.4 Checking valve guides
  88
• 2.5 Renewing valve stem seals
  89
• Lubrication
  91
• 1 Removing and installing parts of the lubrication system
  91
• 1.1 Removing and installing parts of the lubrication system
  91
• 1.2 Removing and installing oil sump
  96
• 1.3 Removing and installing oil pump
  98
• 1.4 Checking oil pressure and oil pressure switch
  101
• Cooling system
  103
• 1 Removing and installing parts of cooling system
  103
• 1.1 Removing and installing parts of cooling system
  103
• 1.2 Parts of cooling system body side
  104
• 1.3 Parts of cooling system engine side
  107
• 1.4 Coolant hose connection diagram
  112
• 1.5 Draining and filling cooling system
  113
• 1.6 Removing and installing radiator
  115
• 1.7 Removing and installing coolant pump
  116
• Fuel supply system
  118
• 1 Removing and installing parts of fuel supply system
  118
• 1.1 Removing and installing parts of fuel supply system
  118
• 1.2 Removing and installing fuel tank with its attachments and fuel filter
  119
• 1.3 Safety precautions when working on the fuel supply system
  123
• 1.4 Rules for cleanliness
  124
• 1.5 Removing and installing fuel delivery unit
  124
• 1.6 Removing and installing fuel tank
  126
• 1.7 Crash fuel shut-off
  127
• 1.8 Checking fuel pump
  128
• 2 Accelerator mechanism
  134
• 2.1 Accelerator mechanism
  134
• 2.2 Servicing accelerator mechanism
  135
• 2.3 Adjusting accelerator cable
  135
• 3 Checking electronic power control (EPC)
  138
• 3.1 Checking electronic power control (EPC)
  138
• 4 Activated charcoal filter system
  139
• 4.1 Activated charcoal filter system
  139
• 4.2 Servicing parts of the activated charcoal filter system
  139
• 4.3 Checking fuel tank breather
  141
• Mixture preparation, Injection
  143
• 1 Servicing injection system
  143
• 1.1 Servicing injection system
  143
• 1.2 Fitting locations overview
  143
• 1.3 General notes on injection
  145
• 1.4 Removing and installing parts of the injection system
  146
• 1.5 Dismantling and assembling intake manifold
  154
• 1.6 Dismantling and assembling fuel rail with injectors
  157
• 1.7 Dismantling and assembling air cleaner
  160
• 1.8 Safety precautions
  163
• 1.9 Rules for cleanliness
  165
• 1.10 Technical data
  165
• 2 Checking components
  166
• 2.1 Checking components
  166
• 2.2 Checking injectors
  167
• 2.3 Checking fuel pressure regulator and holding pressure
  169
• 2.4 Adapting functions and components
  172
• 2.5 Interrogating and erasing engine control unit fault memory
  173
• Exhaust system
  175
• 1 Removing and installing parts of exhaust system
  175
• 1.1 Removing and installing parts of exhaust system
  175
• 1.2 Exhaust manifold, front exhaust pipe and catalyst with attachments
  176
• 1.3 Silencer with mountings
  180
• 2 Exhaust gas recirculation system
  182
• 2.1 Exhaust gas recirculation system
  182
• 2.2 Servicing parts of exhaust gas recirculation system
  183
• 2.3 Checking exhaust gas recirculation valve (mechanical)
  185
• 2.4 Servicing parts of exhaust gas recirculation system
  186
• Ignition system
  188
• 1 Servicing ignition system
  188
• 1.1 Servicing ignition system
  188
• 1.2 General notes on ignition system
  188
• 1.3 Removing and installing parts of the ignition system
  189
• 1.4 Safety precautions
  194
• 1.5 Test data, spark plugs
  195