4-cylinder injection engine (1.6 l engine, 4 valves, MPI)

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety regulations for working on fuel supply
  1
• 1.2 Safety measures when working on vehicles with a start/stop system
  1
• 1.4 Safety precautions when working on ignition system
  2
• 1.5 Safety precautions when working on the cooling system
  2
• 2 Identification
  3
• 2.1 Engine number/engine data
  3
• 3 Repair notes
  4
• 3.1 Rules for cleanliness
  4
• 3.2 Foreign objects in engine
  4
• 3.3 Contact corrosion
  4
• 3.4 Pipe/wire routing and attachment
  4
• 3.5 Fitting radiator and condensers
  5
• Removing and installing engine
  6
• 1 Removing and installing engine
  6
• 1.1 Removing engine
  6
• 1.2 Separating engine and gearbox
  15
• 1.3 Securing engine on engine and gearbox support
  19
• 1.4 Installing engine
  21
• 2 Assembly mountings
  25
• 2.1 Assembly overview - assembly mountings
  25
• 2.2 Supporting engine in installation position
  26
• 2.3 Removing and installing motor mounting
  29
• 2.4 Removing and installing gearbox mounting
  30
• 2.5 Removing and installing pendulum support
  32
• 2.6 Checking adjustment of assembly mountings (engine and gearbox mountings)
  32
• 2.7 Adjusting assembly mountings
  33
• Crankshaft group
  35
• 1 Cylinder block (pulley end)
  35
• 1.1 Assembly overview - poly V-belt drive
  35
• 1.2 Removing and installing poly-V belt
  39
• 1.3 Removing and installing tensioner for poly V-belt
  42
• 1.4 Removing and installing vibration damper
  42
• 1.5 Removing and installing engine support
  43
• 1.6 Renewing crankshaft oil seal - belt pulley end
  46
• 2 Cylinder block, gearbox end
  50
• 2.1 Assembly overview - cylinder block, gearbox end
  50
• 2.2 Removing and installing flywheel
  53
• 2.3 Removing and installing drive plate
  54
• 2.4 Removing and installing sealing flange on gearbox side
  56
• 3 Crankshaft
  66
• 3.1 Renewing needle bearing in crankshaft
  66
• 3.2 Measuring axial clearance of crankshaft
  68
• 4 Pistons and conrods
  69
• 4.1 Assembly overview - pistons and conrods
  69
• 4.2 Removing and installing pistons
  71
• 4.3 Checking pistons and cylinder bores
  73
• 4.4 Separating new conrod
  74
• 4.5 Checking radial clearance of conrods
  75
• 4.6 Removing and installing oil spray jets
  75
• Cylinder head, valve gear
  77
• 1 Cylinder head
  77
• 1.1 Assembly overview - cylinder head
  77
• 1.2 Assembly overview - camshaft housing
  79
• 1.3 Removing and installing cylinder head
  80
• 1.4 Removing and installing camshaft housing
  84
• 1.5 Checking compression
  87
• 2 Toothed belt drive
  90
• 2.1 Assembly overview - toothed belt cover
  90
• 2.2 Assembly overview - toothed belt
  91
• 2.3 Checking valve timing
  92
• 2.4 Removing toothed belt from camshaft
  96
• 2.5 Removing and installing toothed belt
  109
• 3 Valve gear
  124
• 3.1 Assembly overview - valve gear
  124
• 3.2 Removing and installing camshaft adjuster
  125
• 3.3 Measuring axial play of camshaft
  130
• 3.4 Removing and installing camshaft oil seal
  131
• 3.5 Removing and installing camshaft control valve 1 N205
  137
• 3.6 Removing and installing valve stem seals
  137
• 4 Inlet and exhaust valves
  144
• 4.1 Checking valve guides
  144
• 4.2 Checking valves
  144
• 4.3 Valve dimensions
  145
• Lubrication
  146
• 1 Sump, oil pump
  146
• 1.1 Assembly overview - sump/oil pump
  146
• 1.2 Removing and installing lower part of sump
  149
• 1.3 Removing and installing oil pump
  152
• 1.4 Removing and installing upper part of sump
  155
• 1.5 Engine oil:
  159
• 2 Engine oil cooler
  160
• 2.1 Assembly overview - engine oil cooler
  160
• 2.2 Removing and installing engine oil cooler
  160
• 3 Crankcase ventilation
  162
• 3.1 Assembly overview - crankcase breather system
  162
• 3.2 Removing and installing oil separator
  163
• 4 Oil filter, oil pressure switch
  165
• 4.1 Assembly overview - oil filter/oil pressure switch
  165
• 4.2 Removing and installing oil pressure switch F1
  165
• 4.3 Checking oil pressure
  166
• 4.4 Removing and installing oil filter housing
  168
• Cooling
  169
• 1 Cooling system/coolant
  169
• 1.1 Connection diagram - coolant hoses
  169
• 1.2 Draining and adding coolant
  171
• 1.3 Checking cooling system for leaks
  175
• 2 Coolant pump, regulation of cooling system
  178
• 2.1 Assembly overview - coolant pump, thermostat
  178
• 2.2 Assembly overview - coolant temperature sender
  180
• 2.3 Removing and installing coolant pump
  182
• 2.4 Removing and installing toothed belt pulley for coolant pump
  186
• 2.5 Removing and installing thermostat
  187
• 2.6 Removing and installing coolant temperature sender G62
  189
• 2.7 Removing and installing radiator outlet coolant temperature sender G83
  190
• 3 Coolant pipes
  192
• 3.1 Assembly overview - coolant pipes
  192
• 3.2 Removing and installing coolant pipes
  192
• 4 Radiator, radiator fan
  195
• 4.1 Assembly overview - radiator/radiator fan
  195
• 4.2 Assembly overview - radiator cowl and radiator fan
  196
• 4.3 Removing and installing radiator
  196
• 4.4 Removing and installing radiator cowl
  199
• 4.5 Removing and installing radiator fan
  200
• Mixture preparation - injection
  201
• 1 Injection system
  201
• 1.1 Overview of fitting locations - injection system
  201
• 1.2 Assembly overview - fuel system
  205
• 2 Injectors
  207
• 2.1 Assembly overview - fuel rail with injectors
  207
• 2.2 Removing and installing fuel rail
  207
• 2.3 Removing and installing injectors
  210
• 2.4 Checking injectors
  210
• 2.5 Cleaning injectors
  213
• 3 Air filter
  215
• 3.1 Assembly overview - air filter housing
  215
• 3.2 Removing and installing air filter housing
  216
• 4 Intake manifold
  218
• 4.1 Assembly overview - intake manifold
  218
• 4.2 Removing and installing intake manifold
  219
• 4.3 Removing and installing throttle valve module GX3
  221
• 4.4 Cleaning throttle valve module GX3
  222
• 5 Senders and sensors
  224
• 5.1 Removing and installing intake manifold sender GX9
  224
• 6 Engine (motor) control unit
  225
• 6.1 Removing and installing engine (motor) control unit J623
  225
• 7 Lambda probe
  231
• 7.1 Assembly overview - Lambda probe
  231
• 7.2 Removing and installing Lambda probe
  232
• Exhaust system
  235
• 1 Exhaust pipes and silencers
  235
• 1.1 Assembly overview - silencers
  235
• 1.2 Separating exhaust pipes from silencers
  241
• 1.3 Removing and installing silencer
  242
• 1.4 Aligning exhaust system free of stress
  245
• 1.5 Check exhaust system for leaks
  246
• 2 Exhaust gas cleaning
  247
• 2.1 Assembly overview - emission control
  247
• 2.2 Removing and installing catalytic converter
  248
• Ignition system
  251
• 1 Ignition system
  251
• 1.1 Assembly overview - ignition system
  251
• 1.2 Test data, spark plugs
  252
• 1.3 Removing and installing ignition coils with output stage
  252
• 1.4 Removing and installing knock sensor
  254
• 1.5 Removing and installing Hall sender
  255
• 1.6 Removing and installing engine speed sender G28
  255