4-cyl. injection engine (1.6 l with bucket tappets)

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 Notes on installing
  8
• 1.4 Tightening torques
  9
• 1.5 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 for air conditioner compressor
  19
• 1.3 Removing and installing ribbed belt
  20
• 2 Removing and installing sealing flanges and flywheel/drive plate
  21
• 2.1 Removing and installing sealing flanges and flywheel/drive plate
  21
• 2.2 Renewing crankshaft oil seal -belt pulley end
  24
• 2.3 Removing and installing front sealing flange
  27
• 2.4 Removing and installing drive plate
  29
• 3 Removing and installing crankshaft
  32
• 3.1 Removing and installing crankshaft
  32
• 3.2 Colour markings
  36
• 3.3 Pulling needle bearing out of crankshaft and driving in
  37
• 3.4 Crankshaft dimensions
  39
• 4 Dismantling and assembling pistons and conrods
  39
• 4.1 Dismantling and assembling pistons and conrods
  39
• 4.2 Piston and cylinder dimensions
  48
• Cylinder head, Valve gear
  49
• 1 Removing and installing cylinder head
  49
• 1.1 Removing and installing cylinder head
  49
• 1.2 Removing and installing cylinder head
  54
• 1.3 Removing and installing toothed belt
  58
• 1.4 Checking semi-automatic toothed belt tensioning roller
  61
• 1.5 Checking compression pressure
  62
• 2 Servicing valve gear
  64
• 2.1 Servicing valve gear
  64
• 2.2 Reworking valve seats
  69
• 2.3 Replacing camshaft oil seal
  71
• 2.4 Removing and installing camshaft
  74
• 2.5 Checking hydraulic bucket tappets
  77
• 2.6 Checking valve guides
  77
• 2.7 Renewing valve guides
  78
• 2.8 Renewing valve stem seals
  79
• Lubrication
  82
• 1 Removing and installing parts of the lubrication system
  82
• 1.1 Removing and installing parts of the lubrication system
  82
• 1.2 Removing and installing sump
  91
• 1.3 Checking oil pressure and oil pressure switch
  98
• Cooling system
  100
• 1 Removing and installing parts of cooling system
  100
• 1.1 Removing and installing parts of cooling system
  100
• 1.2 Parts of cooling system body side
  101
• 1.3 Parts of cooling system engine side
  104
• 1.4 Removing and installing compact bracket
  111
• 1.5 Coolant hose connection diagram
  114
• 1.6 Draining and filling cooling system
  117
• 1.7 Removing and installing radiator
  120
• 1.8 Removing and installing coolant pump
  122
• 1.9 Removing and installing viscous fan coupling
  124
• 1.10 Removing and installing viscous fan coupling bearing bush
  125
• Fuel supply system
  127
• 1 Removing and installing parts of fuel supply system
  127
• 1.1 Removing and installing parts of fuel supply system
  127
• 1.2 Removing and installing fuel tank with its attachments and fuel filter
  128
• 1.3 Safety precautions when working on the fuel supply system
  135
• 1.4 Rules for cleanliness
  136
• 1.5 Removing and installing fuel delivery unit
  137
• 1.6 Removing and installing fuel tank
  140
• 1.7 Crash fuel shut-off
  142
• 1.8 Checking fuel pump
  142
• 1.9 Servicing accelerator mechanism
  150
• 1.10 Adjusting throttle cable
  153
• 2 Electronic power control (EPC)
  155
• 2.1 Electronic power control (EPC)
  155
• 2.2 Function of EPC system
  155
• 2.3 Servicing parts of electronic power control (EPC)
  156
• 3 Activated charcoal filter system
  157
• 3.1 Activated charcoal filter system
  157
• 3.2 Servicing parts of the activated charcoal filter system
  158
• 3.3 Checking fuel tank breather
  162
• Mixture preparation, Injection
  166
• 1 Servicing injection system
  166
• 1.1 Servicing injection system
  166
• 1.2 Fitting locations overview
  166
• 1.3 General notes on injection
  176
• 1.4 Dismantling and assembling intake manifold
  177
• 1.5 Dismantling and assembling air cleaner
  184
• 1.6 Dismantling and assembling intake hose
  186
• 1.7 Dismantling and assembling fuel rail with injectors
  190
• 1.8 Safety precautions
  191
• 1.9 Rules for cleanliness
  193
• 1.10 Technical data
  193
• 2 Checking components
  193
• 2.1 Checking components
  193
• 2.2 Checking spray pattern and checking for leaks
  193
• 2.3 Checking fuel pressure regulator and holding pressure
  196
• 2.4 Checking intake manifold change-over
  199
• 3 Engine control unit
  200
• 3.1 Engine control unit
  200
• 3.2 Replacing engine control unit
  200
• 3.3 Adapting functions and components
  201
• 3.4 Interrogating and erasing engine control unit fault memory
  201
• Exhaust system
  203
• 1 Removing and installing parts of exhaust system
  203
• 1.1 Removing and installing parts of exhaust system
  203
• 1.2 Exhaust manifold, front exhaust pipe and catalyst with attachments
  204
• 1.3 Silencer with mountings
  210
• 2 Secondary air system
  213
• 2.1 Secondary air system
  213
• 2.2 Function
  213
• 2.3 Removing and installing parts of the secondary air system
  214
• 2.4 Checking combi-valve
  217
• Ignition system
  219
• 1 Servicing ignition system
  219
• 1.1 Servicing ignition system
  219
• 1.2 General notes on ignition system
  219
• 1.3 Removing and installing parts of the ignition system
  220
• 1.4 Safety precautions
  222
• 1.5 Test data, spark plugs
  223