4-cylinder Injection engine (1.6 l engine, direct injection)

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Engine number
  1
• 1.2 Engine data
  2
• Removing and installing engine
  3
• 1 Removing and installing engine
  3
• 1.1 Removing engine
  4
• 1.2 Securing engine to engine and gearbox support VAS 6095
  14
• 1.3 Installing engine
  16
• 1.4 Checking and adjusting assembly mounting
  20
• 1.5 Assembly mountings
  22
• Crankshaft group
  24
• 1 Dismantling and assembling engine
  24
• 1.1 Overview
  24
• 1.2 Belt drive - Assembly overview
  26
• 1.3 Chain drive - Assembly overview
  27
• 1.4 Removing and installing poly V-belt
  29
• 1.5 Removing and installing control housing
  30
• 2 Removing and installing sealing flange and flywheel
  36
• 2.1 Flywheel end - Assembly overview
  36
• 2.2 Renewing crankshaft oil seal - belt pulley end
  38
• 2.3 Tighten bolt for poly V-belt sprocket - crankshaft
  40
• 2.4 Renewing crankshaft sealing flange -flywheel end-
  42
• 2.5 Removing and installing flywheel
  50
• 3 Removing and installing crankshaft
  52
• 3.1 Crankshaft dimensions
  52
• 4 Dismantling and assembling pistons and conrods
  53
• 4.1 Pistons and conrods - Assembly overview
  53
• 4.2 Check piston
  54
• 4.3 Piston and cylinder dimensions
  55
• Cylinder head, valve gear
  56
• 1 Cylinder head
  56
• 1.1 Cylinder head - Assembly overview
  56
• 1.2 Removing and installing camshaft housing
  59
• 1.3 Removing and installing cylinder head
  63
• 1.4 Checking valve timing
  66
• 1.5 Adjusting valve timing
  68
• 1.6 Check compression pressures
  73
• 2 Repairing valve gear
  76
• 2.1 Valve gear - Assembly overview
  76
• 2.2 Checking camshaft axial clearance
  78
• 2.3 Reworking valve seats
  79
• 2.4 Checking valve guides
  80
• 2.5 Renewing valve stem seals
  81
• Lubrication
  83
• 1 Removing and installing parts of lubrication system
  83
• 1.1 Engine oil
  83
• 1.2 Parts of the lubrication system - Assembly overview
  83
• 1.3 Oil cooler - Assembly overview
  86
• 1.4 Removing and installing oil sump
  87
• 1.5 Removing and installing oil pump
  89
• 1.6 Removing and installing oil cooler
  91
• 1.7 Checking oil pressure and oil pressure switch
  93
• Cooling system
  96
• 1 Removing and installing parts of cooling system
  96
• 1.1 Parts of cooling system - body side - Assembly overview
  96
• 1.2 Parts of cooling system engine side (thermostat side) - Assembly overview
  98
• 1.4 Coolant hose schematic diagram
  99
• 1.5 Draining and filling coolant
  102
• 1.6 Removing and installing radiator fan V7 and radiator fan 2 V177
  105
• 1.7 Removing and installing radiator
  106
• 1.8 Removing and installing coolant pump
  107
• 1.9 Removing and installing thermostat
  109
• 1.10 Check cooling system for leaks:
  112
• Fuel supply system
  115
• 1 Removing and installing parts of fuel supply system
  115
• 1.1 Safety precautions when working on fuel supply system
  115
• 1.2 Rules for cleanliness
  115
• 1.3 Fuel tank - Assembly overview
  116
• 1.4 Emptying fuel tank
  118
• 1.5 Removing and installing fuel tank
  120
• 1.6 Fuel fliter - Assembly overview
  122
• 1.7 Removing and installing fuel filter
  123
• 2 Repairing fuel supply
  125
• 2.1 Safety precautions when working on fuel supply system
  125
• 2.2 Rules for cleanliness
  126
• 2.3 Crash fuel shut-off
  126
• 2.4 Removing and installing fuel delivery unit
  126
• 2.5 Removing and installing fuel gauge sender G
  128
• 2.6 Checking fuel pump
  129
• 2.7 Removing and installing high-pressure pump
  138
• 3 Servicing electronic power control (EPC)
  143
• 3.1 Function of EPC system
  143
• 3.2 Accelerator pedal module - Assembly overview
  143
• 3.3 Removing and installing accelerator pedal module
  144
• 4 Activated charcoal filter system
  146
• 4.1 Functional check
  146
• 4.2 Activated charcoal filter system - Assembly overview
  146
• 4.3 Checking fuel tank breather
  147
• Mixture preparation, Injection
  149
• 1 Repairing injection system
  149
• 1.1 General notes on injection
  149
• 1.2 Safety precautions
  150
• 1.3 Rules for cleanliness
  151
• 1.4 Fitting locations overview
  151
• 1.5 Technical data
  159
• 1.6 Air cleaner/engine cover - Assembly overview
  159
• 1.7 Removing and installing engine cover with air cleaner
  160
• 1.8 Intake manifold - Assembly overview
  161
• 1.9 Removing and installing intake manifold
  163
• 1.10 Fuel rail with injectors - Assembly overview
  166
• 1.11 Removing and installing fuel rail
  167
• 1.12 Removing and installing injectors
  169
• 1.13 Cleaning throttle valve module J338
  173
• 2 Checking components
  175
• 2.1 Check vacuum reservoir in intake manifold for leaks
  175
• 2.2 Check function of intake manifold flap
  176
• 2.3 Checking intake air preheating
  176
• 3 Engine control unit
  178
• 3.1 Reading and erasing engine control unit fault memory
  178
• 3.2 Removing and installing engine control unit
  179
• Exhaust system
  183
• 1 Removing and installing parts of exhaust system
  183
• 1.1 Catalytic converters and attachments - Assembly overview
  184
• 1.2 Silencer with mountings - Assembly overview
  186
• 1.3 Removing and installing exhaust manifold
  186
• 1.4 Removing and installing pre-catalytic converter with exhaust manifold
  188
• 1.5 Connecting and disconnecting front and rear silencers
  190
• 1.6 Aligning exhaust system free of stress
  192
• 2 Exhaust gas recirculation system
  194
• 2.1 Assembly overview - Exhaust gas recirculation system
  194
• 2.2 Removing and installing exhaust gas recirculation valve N18
  195
• Ignition system
  197
• 1 Repairing ignition system
  197
• 1.1 Safety precautions
  197
• 1.2 Assembly overview - ignition system
  197
• 1.3 Removing and installing ignition coils with output stage
  198
• 1.4 Spark plug test data
  199