4-cyl. injection engine Mechanics (1.6 l engine)

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
  11
• 1.6 Assembly mountings
  11
• 1.7 Renewing bonded rubber bushes on subframe
  13
• 1.8 Additional information and removal instructions for vehicles with air conditioner
  14
• Crankshaft group
  16
• 1 Dismantling and assembling engine
  16
• 1.1 Dismantling and assembling engine
  16
• 1.2 Removing and installing ribbed belt
  26
• 2 Removing and installing sealing flange and pressure plate/drive plate
  28
• 2.1 Removing and installing sealing flange and pressure plate/drive plate
  28
• 2.2 Renewing crankshaft oil seal -belt pulley end
  31
• 2.3 Removing and installing front sealing flange
  34
• 2.4 Removing and installing drive plate
  36
• 3 Removing and installing crankshaft
  39
• 3.1 Removing and installing crankshaft
  39
• 3.2 Colour markings
  43
• 3.3 Crankshaft dimensions
  43
• 4 Dismantling and assembling pistons and conrods
  44
• 4.1 Dismantling and assembling pistons and conrods
  44
• 4.2 Piston and cylinder dimensions
  50
• Cylinder head, Valve gear
  51
• 1 Removing and installing cylinder head
  51
• 1.1 Removing and installing cylinder head
  51
• 1.2 Removing, installing and tensioning toothed belt
  55
• 1.3 Checking semi-automatic toothed belt tensioning roller
  58
• 1.4 Removing and installing cylinder head
  59
• 1.5 Checking compression pressures
  63
• 2 Servicing valve gear
  64
• 2.1 Servicing valve gear
  64
• 2.2 Reworking valve seats
  70
• 2.3 Replacing camshaft oil seal
  72
• 2.4 Removing and installing camshaft
  75
• 2.5 Checking hydraulic bucket tappets
  78
• 2.6 Checking valve guides
  79
• 2.7 Renewing valve guides
  80
• 2.8 Renewing valve stem seals
  81
• Lubrication
  84
• 1 Removing and installing parts of the lubrication system
  84
• 1.1 Removing and installing parts of the lubrication system
  84
• 1.2 Removing and installing sump
  92
• 1.3 Checking oil pressure and oil pressure switch
  94
• Cooling system
  97
• 1 Removing and installing parts of cooling system
  97
• 1.1 Removing and installing parts of cooling system
  97
• 1.2 Parts of cooling system body side
  98
• 1.3 Parts of cooling system engine side
  101
• 1.4 Coolant hose connection diagram
  111
• 1.5 Draining and filling cooling system
  114
• 1.6 Removing and installing radiator
  117
• 1.7 Removing and installing coolant pump
  119
• 1.8 Removing and installing thermostat
  121
• Fuel supply system
  123
• 1 Removing and installing parts of fuel supply system
  123
• 1.1 Removing and installing parts of fuel supply system
  123
• 1.2 Removing and installing fuel tank with its attachments and fuel filter
  124
• 1.3 Safety precautions when working on the fuel supply system
  130
• 1.4 Rules for cleanliness
  131
• 1.5 Removing and installing fuel delivery unit
  131
• 1.6 Removing and installing fuel gauge sender
  133
• 1.7 Removing and installing fuel tank
  134
• 1.8 Crash fuel shut-off
  135
• 1.9 Checking fuel pump
  136
• 2 Accelerator mechanism
  144
• 2.1 Accelerator mechanism
  144
• 2.2 Servicing accelerator mechanism
  144
• 2.3 Adjusting throttle cable
  145
• 3 Checking electronic power control (EPC)
  147
• 3.1 Checking electronic power control (EPC)
  147
• 3.2 Function of EPC system
  148
• 3.3 Checking accelerator pedal position sender
  149
• 3.4 Adjusting pedal position sender
  153
• 4 Activated charcoal filter system
  155
• 4.1 Activated charcoal filter system
  155
• 4.2 Function
  155
• 4.3 Servicing parts of the activated charcoal filter system
  156
• 4.4 Checking fuel tank breather
  158
• Exhaust system
  160
• 1 Removing and installing parts of exhaust system
  160
• 1.1 Removing and installing parts of exhaust system
  160
• 1.2 Exhaust manifold, front exhaust pipe and catalyst with attachments
  161
• 1.3 Checking catalyst
  171
• 2 Secondary air system
  173
• 2.1 Secondary air system
  173
• 2.2 Function
  173
• 2.3 Removing and installing parts of the secondary air system
  174
• 2.4 Checking secondary air pump motor
  178
• 2.5 Checking combi-valve
  179
• 2.6 Checking secondary air inlet valve
  181
• 3 Exhaust gas recirculation system
  182
• 3.1 Exhaust gas recirculation system
  182
• 3.2 Servicing parts of exhaust gas recirculation system
  183
• 3.3 Checking exhaust gas recirculation system
  186
• 3.4 Checking potentiometer for exhaust gas recirculation
  188