4-cyl. injection engine (1.6 l)

Chapter overview

• Technical data
  1
• 1 \--- Change history ---
  1
• 2 Technical Data
  2
• 2.1 Engine number
  2
• 2.2 Engine characteristics
  2
• Removing and installing engine
  3
• 1 Engine - remove and install
  3
• 1.1 Removal - recommendations
  6
• 1.2 Engine - fasten to assembly stand
  11
• 1.3 Installation notes
  11
• 1.4 Tightening torques
  12
• 1.5 Engine and gearbox support set - align
  13
• 1.6 Power-drive unit supports
  14
• 1.7 Additional notes and installation works in vehicles with air conditioning
  16
• Crankshaft group
  18
• 1 Engine - assembly and disassembly
  18
• 1.1 Seal lid - replace
  23
• 1.2 Poly-V belt (elastic) - remove and install
  23
• 2 Crankshaft and flywheel flanges - remove and install
  27
• 2.1 Flywheel - remove and install
  28
• 2.2 Crankshaft seal (pulley side) - replace
  29
• 2.3 Crankshaft flange (flywheel side) with Engine speed sensor G28 rotor - replace
  32
• 3 Crankshaft - remove and install
  41
• 3.1 Identifying engine bearing shells
  42
• 3.2 Colour codes
  43
• 3.3 Crankshaft - dimensions
  43
• 4 Pistons and connecting rods - removal and installation
  44
• 4.1 Piston and cylinder - dimensions
  47
• Cylinder head, valve gear
  49
• 1 Cylinder head - assembly and disassembly
  49
• 1.1 Toothed belt semi-automatic tensioning pulley - check
  52
• 1.2 Toothed belt - remove and install, adjust
  53
• 1.3 Cylinder head - remove and install
  58
• 1.4 Compression - check
  62
• 2 Camshaft - repair
  66
• 2.1 Camshaft - check axial clearance
  69
• 2.2 Valve seat - trim
  70
• 2.3 Camshaft seal - replace
  72
• 2.4 Camshaft and cylinder head cover - removal and installation
  75
• 2.5 Valve guides - check
  79
• 2.6 Valve stem sealant - replace
  80
• Lubrication
  84
• 1 Lubrication system components
  84
• 1.1 Lubricating system components - assembly overview
  84
• 1.2 Engine oil
  87
• 1.3 Crankcase - remove and install
  87
• 1.4 Oil filter - replace
  90
• 1.5 Oil pump - remove and install
  92
• 1.6 Oil pressure switch F1 - remove and install
  96
• 1.7 Oil pressure and Oil pressure switch F1 - check
  97
• Cooling
  99
• 1 Cooling system components
  99
• 1.1 Cooling system components, body side
  99
• 1.2 Cooling system components, engine side
  101
• 1.3 Hose connection diagram for cooling system
  104
• 1.4 Cooling system - drainage and replenishment
  104
• 1.5 Cooling system - check air-tightness
  111
• 1.6 Coolant tank flap - check safety valve
  113
• 1.7 Radiator - remove and install
  114
• 1.8 Water pump - remove and install
  117
• Fuel supply system
  120
• 1 Fuel supply system components
  120
• 1.1 Fuel tank components with accessories and fuel filter - removal and installation
  120
• 1.2 Safety measures regarding work on the fuel supply
  124
• 1.3 Cleaning rules
  125
• 1.4 Cold start system components - remove and install
  125
• 1.5 Fuel pump (pre-supply pump) G6 - remove and install
  127
• 1.6 Fuel gauge sensor G - remove and install
  129
• 1.7 Fuel reservoir - remove and install
  130
• 1.8 Fuel reservoir (EU5) - remove and install
  131
• 1.9 Fuel pump (pre-supply pump) G6 - check
  135
• 2 Engine power electronic adjustment (electronic accelerator) - check
  146
• 2.1 Electronic accelerator system operation
  146
• 3 Activated charcoal filter system
  148
• 3.1 Operation
  148
• 3.2 Activated charcoal filter system components - repair
  148
• 3.3 Fuel tank ventilation - check
  149
• Mixture preparation - injection
  151
• 1 Injection system - repair
  151
• 1.1 General instructions regarding the injection system
  151
• 1.2 Component location
  151
• 1.3 Injection components - remove and install
  154
• 1.4 Intake manifold - remove and install
  157
• 1.5 Fuel distributor with injectors - removal and installation
  158
• 1.6 Air filter set - assemble and disassemble
  159
• 1.7 Air filter - remove and install
  160
• 1.8 Safety measures
  160
• 1.9 Cleaning rules
  162
• 1.10 Technical Data
  162
• 2 Component checks
  163
• 2.1 Injection valves - check
  163
• 2.2 Supply system pressure, fuel pressure gauge and residual pressure - check
  165
• 3 READINESS code
  172
• 3.1 Creating and Interpreting the READINESS code
  172
• 4 Engine control unit J623
  173
• 4.1 Engine control unit J623 - remove and install
  173
• 4.2 Adjust components
  173
• 4.3 Check the event memory in the Engine control unit J623 and delete it
  174
• Exhaust system
  177
• 1 Exhaust system components
  177
• 1.2 Rear muffler with supports
  180
• Glow plug system
  182
• 1 Ignition system
  182
• 1.1 General instructions regarding the ignition system
  182
• 1.2 Ignition system components - remove and install
  182
• 1.3 Safety measures
  184
• 1.4 Spark plugs Q - test data
  184