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
  2
• 1.4 Safety precautions when working on the cooling system
  2
• 1.5 Safety precautions when working on ignition system
  2
• 1.6 Safety precautions when working on exhaust system
  3
• 2 Identification
  4
• 2.1 Engine number/engine data
  4
• 3 Repair instructions
  5
• 3.1 Rules for cleanliness
  5
• 3.2 General information
  5
• 3.3 Foreign objects in engine
  6
• 3.4 Contact corrosion
  6
• 3.5 Routing and attachment of lines
  6
• 3.6 Fitting radiator and condensers
  6
• 3.7 Checking vacuum system
  7
• Removing and installing engine
  8
• 1 Removing and installing engine
  8
• 1.1 Removing engine
  8
• 1.2 Separating engine and gearbox
  16
• 1.3 Securing engine on engine and gearbox support
  20
• 1.4 Installing engine
  21
• 2 Assembly mountings
  27
• 2.1 Assembly overview - assembly mountings
  27
• 2.2 Removing and installing engine mounting
  28
• 2.3 Removing and installing gearbox mounting
  30
• 2.4 Removing and installing pendulum support
  31
• 2.5 Supporting engine in installation position
  32
• 2.6 Adjusting assembly mountings
  34
• 2.7 Checking adjustment of assembly mountings (engine and gearbox mountings)
  36
• Crankshaft group
  37
• 1 Cylinder block (pulley end)
  37
• 1.1 Assembly overview - poly V-belt drive
  37
• 1.2 Assembly overview - sealing flange, belt pulley end
  41
• 1.3 Removing and installing poly-V belt
  42
• 1.4 Removing and installing tensioner for poly V-belt
  45
• 1.5 Removing and installing vibration damper
  45
• 1.6 Removing and installing engine support
  46
• 1.7 Renewing crankshaft oil seal - belt pulley end
  49
• 1.8 Removing and installing sealing flange on pulley end
  51
• 2 Cylinder block, gearbox end
  54
• 2.1 Assembly overview - cylinder block, gearbox end
  54
• 2.2 Removing and installing flywheel
  55
• 2.3 Removing and installing sealing flange on gearbox side
  56
• 3 Crankshaft
  64
• 3.1 Crankshaft dimensions
  64
• 3.2 Renewing needle bearing in crankshaft
  64
• 3.3 Measuring axial clearance of crankshaft
  66
• 4 Pistons and conrods
  68
• 4.1 Assembly overview - pistons and conrods
  68
• 4.2 Removing and installing pistons
  70
• 4.3 Checking pistons and cylinder bores
  71
• 4.4 Separating new conrod
  72
• 4.5 Checking radial clearance of conrods
  73
• 4.6 Removing and installing oil spray jets
  73
• Cylinder head, valve gear
  75
• 1 Cylinder head
  75
• 1.1 Assembly overview - cylinder head
  75
• 1.2 Assembly overview - camshaft housing
  77
• 1.3 Removing and installing cylinder head
  78
• 1.4 Removing and installing camshaft housing
  82
• 1.5 Checking compression
  84
• 2 Toothed belt drive
  87
• 2.1 Assembly overview - toothed belt cover
  87
• 2.2 Assembly overview - toothed belt
  88
• 2.3 Checking valve timing
  89
• 2.4 Removing toothed belt from camshaft
  94
• 2.5 Removing and installing toothed belt
  108
• 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
  126
• 3.4 Removing and installing camshaft oil seal
  127
• 3.5 Removing and installing camshaft control valve 1 N205
  132
• 3.6 Removing and installing valve stem seals
  133
• 4 Inlet and exhaust valves
  142
• 4.1 Checking valve guides
  142
• 4.2 Checking valves
  142
• 4.3 Valve dimensions
  143
• Lubrication
  144
• 1 Sump, oil pump
  144
• 1.1 Assembly overview - sump/oil pump
  144
• 1.2 Engine oil:
  146
• 1.3 Removing and installing lower part of sump
  146
• 1.4 Removing and installing upper part of sump
  149
• 1.5 Removing and installing oil pump
  152
• 2 Engine oil cooler
  155
• 2.1 Assembly overview - engine oil cooler
  155
• 2.2 Removing and installing engine oil cooler
  155
• 3 Crankcase ventilation
  157
• 3.1 Assembly overview - crankcase breather system
  157
• 3.2 Removing and installing oil separator
  158
• 4 Oil filter, oil pressure switch
  160
• 4.1 Assembly overview - oil filter/oil pressure switch
  160
• 4.2 Removing and installing oil pressure switch F1
  160
• 4.3 Checking oil pressure
  161
• Cooling
  164
• 1 Cooling system/coolant
  164
• 1.1 Connection diagram - coolant hoses
  164
• 1.2 Draining and adding coolant
  165
• 1.3 Checking cooling system for leaks
  170
• 2 Coolant pump, regulation of cooling system
  173
• 2.1 Assembly overview - coolant pump, thermostat
  173
• 2.2 Assembly overview - coolant temperature sender
  175
• 2.3 Removing and installing coolant pump
  177
• 2.4 Removing and installing toothed belt pulley for coolant pump
  181
• 2.5 Removing and installing thermostat
  182
• 2.6 Removing and installing coolant temperature sender G62
  184
• 2.7 Removing and installing radiator outlet coolant temperature sender G83
  186
• 3 Coolant pipes
  188
• 3.1 Assembly overview - coolant pipes
  188
• 3.2 Removing and installing coolant pipes
  188
• 4 Radiator, radiator fan
  191
• 4.1 Assembly overview - radiator/radiator fan
  191
• 4.2 Assembly overview - radiator cowl and radiator fan
  192
• 4.3 Removing and installing radiator
  192
• 4.4 Removing and installing radiator cowl with radiator fan
  195
• 4.5 Removing and installing radiator fan
  196
• Mixture preparation - injection
  198
• 1 Injection system
  198
• 1.1 Overview of fitting locations - injection system
  198
• 1.2 Assembly overview - fuel system
  202
• 2 Injectors
  204
• 2.1 Assembly overview - fuel rail with injectors
  204
• 2.2 Removing and installing fuel rail
  204
• 2.3 Removing and installing injectors
  206
• 2.4 Cleaning injectors
  207
• 3 Air filter
  209
• 3.1 Assembly overview - air filter housing
  209
• 3.2 Removing and installing air filter housing
  210
• 4 Intake manifold
  212
• 4.1 Assembly overview - intake manifold
  212
• 4.2 Removing and installing intake manifold
  213
• 4.3 Removing and installing throttle valve module GX3
  215
• 4.4 Cleaning throttle valve module GX3
  216
• 5 Senders and sensors
  217
• 5.1 Removing and installing intake manifold sender GX9
  217
• 6 Engine control unit
  218
• 7 Lambda probe
  221
• 7.1 Assembly overview - Lambda probe
  221
• Exhaust system
  223
• 1 Exhaust pipes and silencers
  223
• 1.1 Assembly overview - silencers
  223
• 1.2 Separating exhaust pipes from silencers
  223
• 1.3 Aligning exhaust system free of stress
  224
• 1.4 Checking exhaust system for leaks
  226
• 1.5 Installation position of clamp
  226
• 2 Emission control
  228
• 2.1 Assembly overview - emission control
  228
• 2.2 Removing and installing catalytic converter
  229
• Ignition system
  232
• 1 Ignition system
  232
• 1.1 Assembly overview - ignition system
  232
• 1.2 Test data, spark plugs
  233
• 1.3 Removing and installing ignition coils with output stage
  233
• 1.4 Removing and installing knock sensor 1 G61
  235
• 1.5 Removing and installing Hall sender G40
  236
• 1.6 Removing and installing engine speed sender G28
  236