4-cylinder injection engine (1.4 l engine)

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Engine number
  1
• Removing and installing engine
  2
• 1 Removing and installing engine
  2
• 1.1 Removing engine
  3
• 1.2 Securing engine to assembly stand
  8
• 1.3 Installing engine
  10
• 1.4 Additional information and assembly work for vehicles with air conditioner
  12
• 2 Assembly mountings
  13
• 2.1 Supporting engine in installation position
  13
• 2.2 Specified torques for assembly mountings
  14
• Crankshaft group
  17
• 1 Dismantling and assembling engine
  17
• 1.1 Assembly overview - part I, belt drive
  17
• 1.2 Assembly overview - part II, cylinder block
  20
• 1.3 Removing and installing poly-V belt
  20
• 2 Removing and installing sealing flanges and flywheel or drive plate
  23
• 2.1 Assembly overview
  23
• 2.2 Renewing seal for crankshaft poly V-belt pulley end
  24
• 2.3 Tightening procedure for poly V-belt pulley securing bolt
  26
• 2.4 Renewing crankshaft sealing flange - flywheel end
  28
• 2.5 Crankshaft dimensions
  38
• 3 Dismantling and assembling pistons and conrods
  39
• 3.1 Assembly overview
  39
• 3.2 Piston and cylinder dimensions
  43
• Cylinder head, valve gear
  44
• 1 Dismantling and assembling cylinder head
  44
• 1.1 Assembly overview
  44
• 1.2 Checking valve timing
  47
• 1.3 Removing, installing and tensioning toothed belt
  47
• 1.4 Checking semi-automatic toothed belt tensioning roller
  55
• 1.5 Removing and installing camshaft housing
  58
• 1.6 Removing and installing cylinder head
  63
• 1.7 Checking compression
  70
• 2 Repairing valve gear
  73
• 2.1 Assembly overview
  73
• 2.2 Reworking valve seats
  78
• 2.3 Renewing camshaft oil seals
  80
• 2.4 Checking valve guides
  82
• 2.5 Renewing valve stem seals
  83
• Lubrication
  86
• 1 Removing and installing parts of lubrication system
  86
• 1.1 Engine oil:
  86
• 1.2 Assembly overview
  86
• 1.3 Assembly overview - coolant heated oil separator
  89
• 1.4 Removing and installing coolant heated oil separator
  90
• 1.5 Assembly overview - oil filler neck, engine code BCA
  92
• 1.6 Removing and installing oil sump
  94
• 1.7 Removing and installing oil pump
  97
• 1.8 Checking oil pressure and oil pressure switch
  100
• Cooling
  103
• 1 Removing and installing parts of cooling system
  103
• 1.1 General notes on cooling system
  103
• 1.2 Assembly overview - parts of cooling system, body side
  104
• 1.3 Assembly overview - parts of cooling system, engine side
  106
• 1.4 Coolant hose schematic diagram (engines with no coolant heated oil separator)
  108
• 1.5 Coolant hose schematic diagram (engines with coolant heated oil separator)
  109
• 1.6 Draining and adding coolant
  110
• 1.7 Removing and installing radiator fan V7 and radiator fan 2 V177
  120
• 1.8 Removing and installing radiator
  121
• 1.9 Removing and installing coolant pump
  124
• 1.10 Checking cooling system for leaks
  126
• Mixture preparation - injection
  128
• 1 Repairing injection system
  128
• 1.1 General notes on injection
  128
• 1.2 Safety precautions
  129
• 1.3 Rules for cleanliness
  131
• 1.4 Assembly overview - dismantling and assembling intake manifold
  131
• 1.5 Assembly overview - dismantling and assembling fuel rail with injectors
  132
• 1.6 Assembly overview - air filter housing, engine code BCA
  133
• 1.7 Assembly overview - air filter housing, engine code BUD
  135
• 1.8 Cleaning throttle valve module J338
  138
• 1.9 Removing and installing injectors
  139
• 2 Checking components
  143
• 2.1 Checking intake air preheating
  143
• 2.2 Checking injectors for leaks and quantity injected (vehicles model year ► 2005)
  143
• 2.3 Checking injectors for leaks and quantity injected (vehicles model year 2006 ►)
  147
• 2.4 Checking fuel pressure regulator and holding pressure
  151
• 3 Engine control unit
  154
• 3.1 Removing and installing anti-theft engine control unit
  154
• 3.2 Removing and installing engine control unit
  156
• 3.3 Adapting function and components
  157
• 3.4 Reading and erasing engine control unit fault memory
  158
• Exhaust system
  159
• 1 Removing and installing parts of exhaust system
  159
• 1.1 Assembly overview - engine code BCA
  159
• 1.2 Assembly overview - engine code BUD
  161
• 1.3 Assembly overview - silencers with mountings
  163
• 1.4 Separating front and rear silencers
  164
• 2 Exhaust gas recirculation system
  166
• 2.1 Assembly overview - repairing parts of the exhaust gas recirculation system
  166
• Ignition system
  167
• 1 Repairing ignition system
  167
• 1.1 General notes on ignition system
  167
• 1.2 Assembly overview - parts of ignition system
  167
• 1.3 Removing and installing ignition coils with output stage
  168
• 1.4 Safety precautions
  170