4-cylinder injection engine (1.4 l and 1.6 l engine)

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 Notes on removing
  4
• 1.2 Securing engine to assembly stand
  8
• 1.3 Notes on installing
  8
• 1.4 Aligning engine and gearbox mountings
  10
• 1.5 Specified torques
  11
• 1.6 Assembly mountings
  11
• 1.7 Additional information and assembly work for vehicles with air conditioner
  12
• Crankshaft group
  13
• 1 Dismantling and assembling engine
  13
• 1.1 Assembly overview - parts l and ll
  13
• 1.2 Assembly overview - part I, belt drive
  14
• 1.3 Assembly overview - part II, cylinder block
  15
• 1.4 Removing and installing poly V-belt
  17
• 2 Cylinder block, sealing flange
  19
• 2.1 Assembly overview - aluminium cylinder block
  19
• 2.2 Assembly overview - cast-iron cylinder block
  21
• 2.3 Crankshaft dimensions
  22
• 2.4 Renewing crankshaft oil seal - belt pulley end
  23
• 2.5 Tightening procedure for poly V-belt pulley securing bolt
  24
• 2.6 Removing and installing pressure plate/drive plate
  26
• 2.7 Renewing crankshaft sealing flange - flywheel end
  27
• 3 Pistons and conrods
  36
• 3.1 Assembly overview
  36
• 3.2 Separating new conrods
  38
• 3.3 Piston and cylinder dimensions
  39
• Cylinder head, valve gear
  40
• 1 Cylinder head
  40
• 1.1 Assembly overview
  40
• 1.2 Checking valve timing
  42
• 1.3 Removing, installing and tensioning toothed belt
  43
• 1.4 Checking semi-automatic toothed belt tensioner
  48
• 1.5 Removing and installing camshaft housing
  52
• 1.6 Removing and installing cylinder head
  55
• 1.7 Checking compression
  60
• 2 Valve gear
  63
• 2.1 Assembly overview
  63
• 2.2 Reworking valve seats
  66
• 2.3 Renewing camshaft oil seals
  67
• 2.4 Checking valve guides
  70
• 2.5 Renewing valve stem seals
  71
• Lubrication
  74
• 1 Parts of lubrication system
  74
• 1.1 Engine oil
  74
• 1.2 Assembly overview
  74
• 1.3 Removing and installing oil sump
  77
• 1.4 Removing and installing oil pump
  78
• 1.5 Checking oil pressure and oil pressure switch
  81
• Cooling
  83
• 1 Parts of cooling system
  83
• 1.1 Assembly overview - parts of cooling system, body side
  83
• 1.2 Assembly overview - parts of cooling system, engine side
  85
• 1.3 Coolant hose schematic diagram
  86
• 1.4 Draining and filling coolant
  88
• 1.5 Removing and installing radiator
  90
• 1.6 Removing and installing coolant pump
  91
• Fuel supply system
  94
• 1 Parts of fuel supply system
  94
• 1.1 Assembly overview - fuel tank with attachments and fuel filter
  94
• 1.2 Safety precautions when working on fuel supply system
  97
• 1.3 Rules for cleanliness
  97
• 1.4 Removing and installing fuel delivery unit
  97
• 1.5 Removing and installing fuel gauge sender G
  99
• 1.6 Removing and installing fuel tank
  99
• 1.7 Crash fuel shut-off
  101
• 1.8 Checking fuel pump
  101
• 2 Accelerator mechanism
  108
• 2.1 Assembly overview - accelerator mechanism
  108
• 2.2 Adjusting accelerator cable
  108
• 3 Electronic power control (EPC)
  110
• 3.1 Assembly overview
  110
• 4 Activated charcoal filter system
  111
• 4.1 Assembly overview
  111
• 4.2 Checking fuel tank breather
  112
• Mixture preparation - injection
  114
• 1 Injection system
  114
• 1.1 Assembly overview - parts of injection system
  114
• 1.2 Assembly overview - intake manifold
  117
• 1.3 Assembly overview - fuel rail with injectors
  119
• 1.4 Assembly overview - air filter
  119
• 1.5 Cleaning throttle valve module J338
  122
• 1.6 Safety precautions
  123
• 1.7 Rules for cleanliness
  124
• 1.8 Technical data
  125
• 2 Checking components
  126
• 2.1 Checking injectors
  126
• 2.2 Checking fuel pressure regulator and holding pressure
  128
• 2.3 Checking intake air preheating
  131
• 3 Engine control unit
  133
• 3.1 Removing and installing engine control unit
  133
• Exhaust system
  134
• 1 Parts of the exhaust system
  134
• 1.1 Assembly overview - exhaust manifold with catalytic converter and add-on parts
  134
• 1.2 Assembly overview - silencers with mountings
  137
• 2 Exhaust gas recirculation system
  139
• 2.1 Assembly overview - exhaust gas recirculation system
  139
• 2.2 Checking mechanical exhaust gas recirculation valve
  140
• Ignition system
  142
• 1 Ignition system
  142
• 1.1 Assembly overview - ignition system
  142
• 1.2 Removing and installing ignition coils with output stage
  144
• 1.3 Safety precautions
  145
• 1.4 Test data, spark plugs
  146