4-cylinder injection engine (1.6 l direct injection)

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
  6
• 1.3 Installing engine
  6
• 1.4 Torque settings
  7
• 1.5 Assembly mountings
  8
• 1.6 Additional information and removal instructions for vehicles with air conditioner
  9
• Crankshaft group
  10
• 1 Dismantling and assembling engine
  10
• 1.1 Assembly overview - Part I belt drive
  10
• 1.2 Assembly overview - Part II cylinder block
  11
• 1.3 Removing and installing poly V-belt
  13
• 1.4 Removing and installing timing housing
  15
• 2 Cylinder block, sealing flange
  18
• 2.1 Assembly overview
  18
• 2.2 Renewing crankshaft oil seal for belt pulley end
  20
• 2.4 Renewing crankshaft sealing flange -flywheel end-, vehicles with manual gearbox
  26
• 2.6 Crankshaft dimensions
  39
• 3 Piston and conrod
  41
• 3.1 Assembly overview
  41
• 3.2 Checking piston
  42
• 3.3 Piston and cylinder dimensions
  43
• Cylinder head, valve gear
  44
• 1 Cylinder head
  44
• 1.1 Assembly overview
  45
• 1.2 Checking valve timing
  47
• 1.3 Adjusting valve timing
  49
• 1.4 Removing and installing timing chain and chain drive for oil pump
  53
• 1.5 Removing and installing camshaft housing
  60
• 1.6 Removing and installing cylinder head
  63
• 1.7 Checking compression
  66
• 2 Valve gear
  68
• 2.1 Assembly overview
  68
• 2.2 Checking camshaft axial clearance
  70
• 2.3 Reworking valve seats
  70
• 2.4 Checking valve guides
  72
• 2.5 Renewing valve stem seals
  73
• Lubrication
  75
• 1 Parts of lubrication system
  75
• 1.1 Engine oil
  75
• 1.2 Assembly overview
  75
• 1.3 Removing and installing oil sump
  77
• 1.4 Removing and installing oil pump
  79
• 1.5 Checking oil pressure and oil pressure switch
  82
• Cooling
  84
• 1 Parts of cooling system
  84
• 1.1 Assembly overview - Parts of cooling system, body side
  85
• 1.2 Assembly overview - Parts of cooling system, engine side
  86
• 1.3 Coolant hose schematic diagram
  88
• 1.4 Draining and filling coolant
  89
• 1.5 Removing and installing radiator
  91
• 1.6 Removing and installing coolant pump
  93
• Fuel supply system
  95
• 1 Safety precautions
  95
• 1.1 Safety precautions when working on fuel supply system
  95
• 1.2 Rules for cleanliness
  95
• 1.3 Releasing pressure in high-pressure section
  96
• 2 Fuel tank
  97
• 2.1 Assembly overview - fuel tank
  97
• 2.2 Emptying fuel tank
  98
• 2.3 Removing and installing fuel tank
  101
• 3 Parts of fuel supply system
  104
• 3.1 Removing and installing fuel delivery unit
  104
• 3.2 Removing and installing fuel gauge sender G
  106
• 3.3 Crash fuel shut-off
  106
• 3.4 Checking fuel pump
  107
• 3.5 Removing and installing high-pressure pump
  112
• 4 Electronic power control (EPC)
  118
• 4.1 Function of EPC system
  118
• 4.2 Assembly overview
  119
• 4.3 Removing and installing accelerator module
  119
• 5 Activated charcoal filter system
  121
• 5.1 Function
  121
• 5.2 Checking fuel tank breather
  121
• Mixture preparation - injection
  123
• 1 Injection system
  123
• 1.1 Assembly overview - Intake manifold
  124
• 1.2 Assembly overview - Fuel rail with injectors
  126
• 1.3 Checking vacuum reservoir in intake manifold for leaks
  127
• 1.4 Assembly overview - Air cleaner
  128
• 1.5 Removing and installing air cleaner housing
  129
• 1.6 Cleaning throttle valve module J338
  129
• 1.7 Removing and installing injectors
  130
• 1.8 Safety precautions
  133
• 1.9 Rules for cleanliness
  135
• 1.10 Technical data
  135
• 2 Check components
  136
• 2.1 Checking intake air preheating
  136
• 3 Engine control unit
  137
• 3.1 Removing and installing engine control unit
  137
• 3.2 Removing and installing tamper-proof engine control unit
  138
• Exhaust system
  140
• 1 Parts of the exhaust system
  140
• 1.1 Assembly overview - catalytic converters and attachments, engine code BAG
  141
• 1.3 Assembly overview - Silencer with mountings
  144
• 2 Exhaust gas recirculation system
  145
• 2.1 Assembly overview - Exhaust gas recirculation system
  145
• 2.2 Removing and installing exhaust gas recirculation valve N18
  146
• Ignition system
  148
• 1 Ignition system
  148
• 1.1 General notes on ignition system
  148
• 1.2 Assembly overview - Ignition system
  149
• 1.3 Removing and installing ignition coils with output stage
  149
• 1.4 Safety precautions
  150
• 1.5 Spark plug test data
  151