4-cylinder injection engine (1.4 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 General notes on removal and installation of the engine
  3
• 1.2 Removing engine
  5
• 1.3 Installing engine
  10
• 1.4 Specified torques
  12
• 1.5 Additional information and assembly work for vehicles with air conditioner
  13
• Crankshaft group
  14
• 1 Dismantling and assembling engine
  14
• 1.1 General notes on crankshaft group
  14
• 1.2 Rules for cleanliness
  15
• 1.3 Part I: assembly overview - toothed belt drive
  15
• 1.4 Removing and installing poly V-belt
  17
• 1.5 Tightening procedure for securing bolt of poly V-belt pulley
  19
• 1.6 Part II: assembly overview - cylinder block
  20
• 2 Cylinder block, sealing flange
  22
• 2.1 Assembly overview - aluminium cylinder block
  22
• 2.2 Renewing crankshaft oil seal - pulley end
  24
• 2.3 Renewing crankshaft sealing flange - flywheel end
  25
• 2.4 Crankshaft dimensions
  34
• 3 Pistons and conrods
  35
• 3.1 Assembly overview - pistons and conrods
  35
• 3.2 Piston and cylinder dimensions
  38
• Cylinder head, valve gear
  39
• 1 Cylinder head
  39
• 1.1 General notes on cylinder head, valve gear
  39
• 1.2 Rules for cleanliness
  39
• 1.3 Assembly overview - cylinder head
  40
• 1.4 Checking valve timing
  42
• 1.5 Removing, installing and tensioning toothed belts
  43
• 1.6 Checking semi-automatic toothed belt tensioning rollers
  48
• 1.7 Removing and installing camshaft housing
  51
• 1.8 Removing and installing cylinder head
  55
• 1.9 Checking compression
  61
• 2 Valve gear
  64
• 2.1 Assembly overview - valve gear
  64
• 2.2 Reworking valve seats
  67
• 2.3 Renewing camshaft oil seals
  69
• 2.4 Checking valve guides
  71
• 2.5 Renewing valve stem seals
  72
• Lubrication
  74
• 1 Parts of lubrication system
  74
• 1.1 General notes on lubrication
  74
• 1.2 Rules for cleanliness
  74
• 1.3 Engine oil
  74
• 1.4 Assembly overview - parts of lubrication system
  75
• 1.5 Removing and installing sump
  77
• 1.6 Removing and installing oil pump
  79
• 1.7 Checking oil pressure and oil pressure switch F1
  82
• Cooling
  85
• 1 Parts of cooling system
  85
• 1.1 General notes on cooling system
  85
• 1.2 Safety precautions
  85
• 1.3 Rules for cleanliness
  86
• 1.4 Assembly overview - parts of cooling system (radiator with two fans), body side
  86
• 1.5 Assembly overview - parts of cooling system - thermostat side
  88
• 1.6 Assembly overview - parts of cooling system - coolant pump side
  89
• 1.7 Coolant hose schematic diagram (up to MY 2009)
  90
• 1.8 Coolant hose schematic diagram (from MY 2010)
  91
• 1.9 Draining and filling with coolant
  92
• 1.10 Removing and installing radiator fan V7 and radiator fan 2 V177
  95
• 1.11 Removing and installing radiator
  96
• 1.12 Removing and installing coolant pump
  98
• 1.13 Checking cooling system for leaks
  100
• Fuel supply system
  103
• 1 Parts of fuel supply system
  103
• 1.1 General notes on fuel supply system
  103
• 1.2 Safety precautions when working on fuel supply system
  104
• 1.3 Rules for cleanliness
  104
• 1.4 Crash fuel shut-off
  105
• 1.5 Assembly overview - fuel tank with attachments and fuel filter
  105
• 1.6 Emptying fuel tank
  107
• 1.7 Removing and installing fuel delivery unit
  110
• 1.8 Removing and installing fuel gauge sender G
  112
• 1.9 Removing and installing fuel tank
  113
• 1.10 Checking fuel pump G6
  116
• 1.11 Assembly overview - fuel filter with attachments
  127
• 1.12 Removing and installing fuel filter
  129
• 1.13 Bleeding fuel system
  130
• 2 Electronic power control (EPC)
  134
• 2.1 Function of EPC system
  134
• 2.2 Assembly overview - accelerator pedal module
  134
• 2.3 Removing and installing accelerator module
  135
• 3 Activated charcoal filter system
  138
• 3.1 General notes on activated charcoal filter system
  138
• 3.2 Function
  138
• 3.3 Assembly overview - activated charcoal filter system
  138
• 3.4 Checking fuel tank breather
  139
• Mixture preparation - injection
  141
• 1 Injection system
  141
• 1.1 General notes on injection
  142
• 1.2 Safety precautions when working on injection system
  143
• 1.3 Rules for cleanliness
  144
• 1.4 Assembly overview - intake manifold
  144
• 1.5 Assembly overview - fuel rail with injectors
  146
• 1.6 Assembly overview - air filter housing
  146
• 1.7 Removing and installing air filter housing
  148
• 1.8 Cleaning throttle valve module J338
  150
• 1.9 Removing and installing injectors
  151
• 2 Checking components
  154
• 2.1 Checking injectors for leaks and quantity injected
  154
• 3 Engine control unit J623
  158
• 3.1 Removing and installing engine control unit
  158
• Exhaust system
  163
• 1 Removing and installing parts of exhaust system
  163
• 1.1 General notes on exhaust system
  163
• 1.2 Assembly overview - catalytic converters and attachments
  165
• 1.3 Assembly overview - silencers with mountings
  167
• 1.4 Separating and joining front and rear silencers
  168
• 1.5 Aligning exhaust system free of stress
  169
• Ignition system
  171
• 1 Ignition system
  171
• 1.1 General notes on ignition system
  171
• 1.2 Safety precautions when working on ignition system
  171
• 1.3 Assembly overview - ignition system
  172
• 1.4 Removing and installing ignition coils with output stage
  173
• 1.5 Test data, spark plugs
  176