4-cyl. injection engine (1.6 ltr. with roller rocker finger)

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
  5
• 1.3 Notes on installing
  8
• 1.4 Tightening torques
  9
• 1.5 Front engine mounting
  10
• 1.6 Additional information and removal instructions for vehicles with air conditioner
  10
• Crankshaft group
  12
• 1 Dismantling and assembling engine
  12
• 1.1 Dismantling and assembling engine
  12
• 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
  21
• 2.1 Removing and installing sealing flanges and flywheel
  21
• 2.2 Renewing crankshaft oil seal -belt pulley end
  24
• 2.3 Removing and installing front sealing flange
  27
• 3 Removing and installing crankshaft
  30
• 3.1 Removing and installing crankshaft
  30
• 3.2 Colour markings
  34
• 3.3 Pulling needle bearing out of crankshaft and driving in
  35
• 3.4 Crankshaft dimensions
  37
• 4 Dismantling and assembling pistons and conrods
  38
• 4.1 Dismantling and assembling pistons and conrods
  38
• 4.2 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 Removing and installing cylinder head
  50
• 1.3 Removing and installing toothed belt
  54
• 1.4 Checking semi-automatic toothed belt tensioning roller
  57
• 1.5 Checking compression pressure
  58
• 2 Servicing valve gear
  60
• 2.1 Servicing valve gear
  60
• 2.2 Reworking valve seats
  65
• 2.3 Replacing camshaft oil seal
  67
• 2.4 Removing and installing camshaft
  70
• 2.5 Checking valve guides
  74
• 2.6 Renewing valve stem seals
  75
• Lubrication
  78
• 1 Removing and installing parts of the lubrication system
  78
• 1.1 Removing and installing parts of the lubrication system
  78
• 1.2 Removing and installing sump
  87
• 1.3 Checking oil pressure and oil pressure switch
  93
• Cooling system
  95
• 1 Removing and installing parts of cooling system
  95
• 1.1 Removing and installing parts of cooling system
  95
• 1.2 Parts of cooling system body side
  96
• 1.3 Parts of cooling system engine side
  99
• 1.4 Removing and installing compact bracket
  103
• 1.5 Coolant hose connection diagram
  106
• 1.6 Draining and filling cooling system
  107
• 1.7 Removing and installing radiator
  110
• 1.8 Removing and installing coolant pump
  112
• 1.9 Removing and installing viscous fan coupling
  113
• 1.10 Removing and installing viscous fan coupling bearing bush
  115
• Fuel supply system
  117
• 1 Removing and installing parts of fuel supply system
  117
• 1.1 Removing and installing parts of fuel supply system
  117
• 1.2 Removing and installing fuel tank with its attachments and fuel filter
  118
• 1.3 Safety precautions when working on the fuel supply system
  125
• 1.4 Rules for cleanliness
  126
• 1.5 Removing and installing fuel delivery unit
  126
• 1.6 Removing and installing fuel gauge sender
  128
• 1.7 Removing and installing fuel tank
  129
• 1.8 Crash fuel shut-off
  130
• 1.9 Checking fuel pump
  131
• 2 Electronic power control (EPC)
  138
• 2.1 Electronic power control (EPC)
  138
• 2.2 Function of EPC system
  138
• 2.3 Servicing parts of electronic power control (EPC)
  139
• 3 Activated charcoal filter system
  140
• 3.1 Activated charcoal filter system
  140
• 3.2 Function
  140
• 3.3 Servicing parts of the activated charcoal filter system
  141
• 3.4 Checking fuel tank breather
  143
• Mixture preparation, Injection
  146
• 1 Servicing injection system
  146
• 1.1 Servicing injection system
  146
• 1.2 Fitting locations overview
  146
• 1.3 General notes on injection
  153
• 1.4 Dismantling and assembling intake manifold
  154
• 1.5 Dismantling and assembling air cleaner
  158
• 1.6 Dismantling and assembling intake hose
  160
• 1.7 Dismantling and assembling fuel rail with injectors
  162
• 1.8 Safety precautions
  163
• 1.9 Rules for cleanliness
  164
• 1.10 Technical data
  164
• 2 Checking components
  165
• 2.1 Checking components
  165
• 2.2 Checking spray pattern and checking for leaks
  165
• 2.3 Checking fuel pressure regulator and holding pressure
  167
• 2.4 Checking intake manifold change-over
  169
• 3 Engine control unit
  170
• 3.1 Engine control unit
  170
• 3.2 Replacing engine control unit
  170
• 3.3 Adapting functions and components
  171
• 3.4 Interrogating and erasing engine control unit fault memory
  172
• Exhaust system
  174
• 1 Removing and installing parts of exhaust system
  174
• 1.1 Removing and installing parts of exhaust system
  174
• 1.2 Exhaust manifold, front exhaust pipe and catalyst with attachments
  175
• 1.3 Silencer with mountings
  179
• 2 Secondary air system
  181
• 2.1 Secondary air system
  181
• 2.2 Function
  182
• 2.3 Removing and installing parts of the secondary air system
  182
• 2.4 Checking combi-valve
  185
• 3 Exhaust gas recirculation system
  187
• 3.1 Exhaust gas recirculation system
  187
• 3.2 Servicing parts of exhaust gas recirculation system
  187
• Ignition system
  189
• 1 Servicing ignition system
  189
• 1.1 Servicing ignition system
  189
• 1.2 General notes on ignition system
  189
• 1.3 Removing and installing parts of the ignition system
  190
• 1.4 Safety precautions
  193
• 1.5 Test data, spark plugs
  194