4-cylinder fuel injection engine

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Engine number
  1
• 1.2 Engine characteristics
  1
• Cylinders, engine block, support, cover
  3
• 1 Engine - remove and install
  3
• 1.1 Removal
  4
• 1.2 Engine - fix on the assembly support
  9
• 1.3 Installation
  9
• 1.4 Tightening torque
  11
• 1.5 Engine and transmission bracket set - align
  12
• 1.6 Drive train supports (torques)
  13
• 1.7 Additional indications related to installation
  15
• Crankshaft, pistons
  16
• 1 Engine - disassemble and assemble
  16
• 1.1 Seal cover - replace
  21
• 1.2 Poly-V belt - remove and install
  21
• 1.3 Poly-V belt (elastic) - remove and install
  23
• 2 Sealing flanges and flywheel - Remove and install
  27
• 2.1 Crankshaft sealant (pulley side) - replace
  28
• 2.2 Crankshaft flange (flywheel side) - replace
  31
• 3 Crankshaft - remove and install
  39
• 3.1 Identification of engine bearing shells
  40
• 3.2 Color codes
  40
• 3.3 Crankshaft dimensions
  41
• 4 Pistons and rods - remove and install
  42
• 4.1 Piston and cylinder dimensions
  45
• Cylinder head, ?Valve gear
  47
• 1 Cylinder head - disassemble and assemble
  47
• 1.1 Semi-automatic tensioner pulley of the toothed belt - check
  49
• 1.2 Tooth belt - remove, install, and adjust
  52
• 1.3 Cylinder head - remove and install
  57
• 1.4 Compression - check
  62
• 2 Servicing camshaft - replace
  65
• 2.1 Camshaft - check axial clearance
  67
• 2.2 Valve seat - rework
  68
• 2.3 Camshaft seal - replace
  70
• 2.4 Head and camshaft cover - remove and install
  72
• 2.5 Valve guides - check
  74
• 2.6 Valve stem seal - replace
  76
• Lubrication system
  78
• 1 Lubrication system components - remove and install
  78
• 1.1 Oil sump - remove and install
  81
• 1.2 Oil pump - remove and install
  84
• 1.3 Oil pressure and Oil pressure switch F1 - Check
  87
• Cooling system
  89
• 1 Cooling system components - remove and install
  89
• 1.1 Cooling system components on the body side
  90
• 1.2 Cooling system components on the engine side
  91
• 1.3 Cooling system hose connections diagram
  93
• 1.4 Cooling system - drain and fill
  96
• 1.5 Radiator - remove and install
  100
• 1.6 Water pump - remove and install
  102
• Fuel supply system
  104
• 1 Fuel supply system components - remove and install
  104
• 1.1 Fuel tank components with accessories and fuel filter - remove and install
  105
• 1.2 Safety measures for work on the fuel supply
  106
• 1.3 Rules for cleanliness
  107
• 1.4 Quick connection “Pop Top” - Disconnect and connect
  107
• 1.5 Fuel pump for cold start V263 - Remove and install
  109
• 1.6 Fuel system pressurization pump G6 - Remove and install
  114
• 1.7 Fuel level sensor G - Remove and install
  116
• 1.8 Fuel tank - remove and install
  117
• 1.9 Fuel system pressurization pump G6 - Check
  120
• 2 Engine power electronic regulation (electronic throttle) - check
  127
• 2.1 Electronic throttle system operation
  127
• 3 Activated charcoal filter system
  129
• 3.1 Function
  129
• 3.2 Activated charcoal filter system components - repair
  130
• 3.3 Fuel tank ventilation - check
  130
• Fuel supply - injection system
  132
• 1 Injection system - repair
  132
• 1.1 General indications about injection
  132
• 1.2 Component location
  132
• 1.3 Injection components - remove and install
  136
• 1.4 Intake manifold - remove and install
  141
• 1.5 Fuel distributor with injectors - remove and install
  142
• 1.6 Air filter - disassemble and assemble
  142
• 1.7 Safety measures
  146
• 1.8 Rules for cleanliness
  147
• 1.9 Technical data
  147
• 2 Component check
  149
• 2.1 Injection valves - check
  149
• 2.2 Fuel pressure regulator and remaining pressure - check
  152
• 3 READINESS Code
  156
• 3.1 Read and generate READINESS code
  156
• 4 Engine control unit J623
  157
• 4.1 Engine control unit J623 - remove and install
  157
• 4.2 Fasten components
  158
• 4.3 Consult fault memory of the Engine control unit J623 and erase
  158
• Exhaust system
  161
• 1 Removal and installation of the exhaust system parts
  161
• 1.1 Exhaust manifold, front exhaust pipe with catalyst and attachments
  161
• 1.2 Muffler with supports
  164
• Ignition system
  166
• 1 Ignition system: Repair
  166
• 1.1 General indications about the ignition system
  166
• 1.2 Injection system components - remove and install
  166
• 1.3 Safety measures
  168
• 1.4 Test data, spark plugs
  168