4-cylinder injection engine (1.6 l engine) Mechanics

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Engine number
  1
• 1.2 Engine data
  1
• Removing and installing engine
  2
• 1 Removing and installing engine
  2
• 1.1 Notes on removing
  3
• 1.2 Securing engine to assembly stand
  7
• 1.3 Notes on installing
  8
• 1.4 Torque settings
  9
• 1.5 Aligning engine and gearbox mountings
  10
• 1.6 Torque settings for assembly mountings
  10
• 1.7 Additional information and removal instructions for vehicles with air conditioner
  11
• Crankshaft group
  13
• 1 Dismantling and assembling engine
  13
• 1.1 Assembly overview
  13
• 1.2 Removing and installing poly-V-belt
  18
• 2 Removing and installing sealing flange and pressure plate/drive plate
  20
• 2.1 Renewing crankshaft oil seal - belt pulley end
  21
• 2.2 Removing and installing front sealing flange
  23
• 2.3 Removing and installing drive plate
  26
• 3 Removing and installing crankshaft
  28
• 3.1 Crankshaft dimensions
  29
• 4 Dismantling and assembling pistons and conrods
  30
• 4.1 Checking pistons, piston rings and cylinder bores
  31
• 4.2 Piston and cylinder dimensions
  32
• Cylinder head, valve gear
  33
• 1 Removing and installing cylinder head
  33
• 1.1 Removing, installing and tensioning toothed belts
  34
• 1.2 Checking semi-automatic toothed belt tensioning roller
  39
• 1.3 Removing and installing cylinder head
  40
• 1.4 Checking compression
  43
• 2 Repairing valve gear
  45
• 2.1 Reworking valve seats
  47
• 2.2 Renewing camshaft oil seal
  49
• 2.3 Removing and installing camshaft
  51
• 2.4 Checking hydraulic bucket tappets
  53
• 2.5 Checking valve guides
  54
• 2.6 Renewing valve guides
  55
• 2.7 Renewing valve stem seals
  56
• Lubrication
  59
• 1 Removing and installing parts of lubrication system
  59
• 1.1 Engine oil
  59
• 1.2 Assembly overview - parts of lubrication system
  59
• 1.3 Assembly overview - oil filter bracket
  61
• 1.4 Removing and installing sump
  62
• 1.5 Checking oil pressure and oil pressure switch
  64
• Cooling
  67
• 1 Removing and installing parts of cooling system
  67
• 1.1 Parts of cooling system - body side
  67
• 1.2 Parts of cooling system - engine side
  69
• 1.3 Coolant hose schematic diagram
  73
• 1.4 Draining and filling coolant
  75
• 1.5 Removing and installing radiator
  77
• 1.6 Removing and installing coolant pump
  79
• 1.7 Removing and installing thermostat
  80
• 1.8 Electronically regulated cooling system
  82
• 1.9 Checking electronically regulated cooling system
  82
• 1.10 Dismantling and assembling coolant distribution housing
  83
• 1.11 Checking map-controlled engine cooling thermostat
  84
• Fuel supply system
  88
• 1 Removing and installing parts of fuel supply system
  88
• 1.1 Removing and installing fuel tank with attachments and fuel filter
  89
• 1.2 Safety precautions when working on fuel supply system
  91
• 1.3 Rules for cleanliness
  91
• 1.4 Removing and installing fuel delivery unit
  92
• 1.5 Removing and installing fuel gauge sender G
  93
• 1.6 Removing and installing fuel tank
  93
• 1.7 Checking fuel pump
  95
• 2 Accelerator mechanism
  102
• 2.1 Repairing accelerator mechanism
  102
• 2.2 Adjusting accelerator cable
  102
• 3 Checking electronic power control (EPC)
  104
• 3.1 Function of EPC system
  104
• 3.2 Checking accelerator pedal position sender
  105
• 4 Activated charcoal filter system
  108
• 4.1 Repairing parts of the activated charcoal filter system
  108
• 4.2 Checking solenoid valve 1 for activated charcoal filter
  110
• 4.3 Checking fuel tank breather
  113
• Exhaust system
  116
• 1 Removing and installing parts of exhaust system
  116
• 1.2 Silencer with mountings
  120
• 1.3 Checking catalytic converter
  121
• 2 Secondary air system
  124
• 2.1 Function
  124
• 2.2 Removing and installing parts of secondary air system
  124
• 2.3 Check secondary air system
  126
• 2.4 Checking secondary air pump motor V101
  128
• 2.5 Checking combination valve
  133
• 2.6 Checking secondary air inlet valve N112
  134
• 3 Exhaust gas recirculation system
  137
• 3.1 Repairing parts of exhaust gas recirculation system
  137
• 3.2 Checking exhaust gas recirculation potentiometer G212
  139