4-cylinder injection engine (1.4 l, 4 valves)

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Engine number
  1
• 1.2 Engine data
  1
• Removing and installing engine
  3
• 1 Removing and installing engine
  3
• 1.1 Removing engine
  3
• 1.2 Securing engine to assembly stand
  7
• 1.3 Installing engine
  7
• 1.4 Specified torques
  8
• 1.5 Assembly mountings
  9
• 1.6 Additional information and assembly work for vehicles with air conditioner
  10
• Crankshaft group
  11
• 1 Dismantling and assembling engine
  11
• 1.1 Assembly overview – parts l and ll
  11
• 1.2 Removing and installing poly V-belt
  14
• 1.3 Checking valve timing
  15
• 1.4 Removing, installing and tensioning toothed belt
  15
• 1.5 Checking semi-automatic toothed belt tensioner
  21
• 1.6 Checking coupling drive tensioning roller
  24
• 2 Cylinder block, sealing flange and flywheel/drive plate
  26
• 2.1 Assembly overview
  26
• 2.2 Renewing crankshaft oil seal on belt pulley end
  28
• 2.3 Poly V-belt pulley securing bolt tightening procedure
  29
• 2.4 Removing and installing drive plate
  30
• 2.5 Renewing crankshaft sealing flange - flywheel end
  32
• 2.6 Crankshaft dimensions
  39
• 3 Dismantling and assembling pistons and conrods
  41
• 3.1 Piston and cylinder dimensions
  44
• Cylinder head, valve gear
  45
• 1 Removing and installing cylinder head
  45
• 1.1 Removing and installing camshaft housing
  47
• 1.2 Removing and installing cylinder head
  49
• 1.3 Checking compression
  53
• 2 Repairing valve gear
  56
• 2.1 Reworking valve seats
  59
• 2.2 Renewing camshaft oil seals
  60
• 2.3 Checking valve guides
  62
• 2.4 Renewing valve stem seals
  63
• Lubrication
  65
• 1 Parts of lubrication system
  65
• 1.1 Engine oil
  65
• 1.2 Assembly overview
  65
• 1.3 Removing and installing oil sump
  68
• 1.4 Removing and installing oil pump
  70
• 1.5 Checking oil pressure and oil pressure switch
  73
• Cooling
  75
• 1 Removing and installing parts of cooling system
  75
• 1.1 Parts of cooling system, body side
  75
• 1.2 Parts of cooling system - engine side
  77
• 1.3 Coolant hose schematic diagram
  79
• 1.4 Draining and filling coolant
  80
• 1.5 Removing and installing radiator
  82
• 1.6 Removing and installing coolant pump
  83
• Fuel supply system
  86
• 1 Removing and installing parts of fuel supply system
  86
• 1.1 Removing and installing fuel tank with attachments and fuel filter
  86
• 1.2 Safety precautions when working on fuel supply system
  89
• 1.3 Rules for cleanliness
  89
• 1.4 Removing and installing fuel delivery unit
  90
• 1.5 Removing and installing fuel tank
  91
• 1.6 Crash fuel shut-off
  92
• 1.7 Checking fuel pump
  92
• 2 Accelerator mechanism
  99
• 2.1 Assembly overview
  99
• 2.2 Adjusting accelerator cable
  100
• 3 Checking electronic power control (EPC)
  101
• 3.1 Assembly overview
  101
• 4 Activated charcoal filter system
  102
• 4.1 Repairing parts of activated charcoal filter system
  102
• 4.2 Checking fuel tank breather
  102
• Mixture preparation - injection
  105
• 1 Repairing injection system
  105
• 1.1 Overview of fitting locations
  105
• 1.2 General notes on injection
  106
• 1.3 Removing and installing parts of the injection system
  107
• 1.4 Dismantling and assembling intake manifold
  110
• 1.5 Dismantling and assembling fuel rail with injectors
  111
• 1.6 Dismantling and assembling air filter
  111
• 1.7 Cleaning throttle valve module J338
  113
• 1.8 Safety precautions
  114
• 1.9 Rules for cleanliness
  115
• 1.10 Technical data
  116
• 2 Checking components
  117
• 2.1 Checking injectors
  117
• 2.2 Checking fuel pressure regulator and holding pressure
  118
• 2.3 Adapting functions and components
  121
• 2.4 Reading and erasing engine control unit fault memory
  122
• Exhaust system
  123
• 1 Removing and installing parts of exhaust system
  123
• 1.1 Assembly overview - exhaust manifold with catalytic converter and add-on parts
  123
• 1.2 Assembly overview - silencers with mountings
  125
• 2 Exhaust gas recirculation system
  126
• 2.1 Assembly overview - exhaust gas recirculation system
  126
• 2.2 Checking exhaust gas recirculation valve N18
  127
• Ignition system
  129
• 1 Repairing ignition
  129
• 1.1 General notes on ignition system
  129
• 1.2 Assembly overview - parts of ignition system
  129
• 1.3 Safety precautions
  131
• 1.4 Test data, spark plugs
  132