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

Chapter overview

• Technical data
  1
• 1 Safety instructions
  1
• 1.1 Safety precautions when working on fuel supply system
  1
• 1.3 Safety precautions when working on cooling system
  2
• 1.4 Safety precautions when working on ignition system
  2
• 2 Identification
  3
• 2.1 Engine number, engine data
  3
• 3 Repair instructions
  4
• 3.1 Rules for cleanliness
  4
• 3.2 Foreign objects in engine
  4
• 3.3 Contact corrosion
  4
• 3.4 Routing and securing lines
  5
• 3.5 Installing coolers, condensers and radiators
  5
• Removing and installing engine
  6
• 1 Removing and installing engine
  6
• 1.1 Removing engine
  6
• 1.2 Separating engine and gearbox
  11
• 1.3 Securing engine on engine and gearbox support
  15
• 1.4 Installing engine
  16
• 2 Assembly mountings
  19
• 2.1 Assembly overview - assembly mountings
  19
• 2.2 Removing and installing engine mountings
  21
• 2.3 Supporting engine in installation position
  25
• 2.4 Adjusting assembly mountings
  34
• Crankshaft group
  36
• 1 Cylinder block (pulley end)
  36
• 1.1 Assembly overview - poly V-belt drive
  36
• 1.2 Assembly overview - cylinder block (pulley end)
  37
• 1.3 Removing and installing poly V-belt
  40
• 1.4 Removing and installing tensioner for poly V-belt
  40
• 1.5 Removing and installing vibration damper
  41
• 1.6 Removing and installing ancillary bracket
  44
• 1.7 Renewing crankshaft oil seal - belt pulley end
  45
• 2 Cylinder block, gearbox end
  48
• 2.1 Assembly overview - cylinder block, gearbox end
  48
• 2.2 Removing and installing sealing flange on gearbox side
  49
• 3 Crankshaft
  58
• 3.1 Assembly overview - crankshaft
  58
• 3.2 Crankshaft dimensions
  59
• 4 Pistons and conrods
  60
• 4.1 Assembly overview - pistons and conrods
  60
• 4.2 Checking piston and cylinder bore
  61
• Cylinder head, valve gear
  63
• 1 Cylinder head
  63
• 1.1 Assembly overview - cylinder head
  63
• 1.2 Removing and installing cylinder head
  64
• 1.3 Removing and installing camshaft housing
  67
• 1.4 Checking compression
  69
• 2 Cover for timing chain
  72
• 2.1 Removing and installing valve timing housing (timing case)
  72
• 3 Chain drive
  75
• 3.1 Removing and installing timing chain and chain drive for oil pump
  75
• 3.2 Checking valve timing
  82
• 3.3 Adjusting valve timing
  83
• 4 Valve gear
  90
• 4.1 Assembly overview - valve gear
  90
• 4.2 Measuring axial play of camshaft
  92
• 4.3 Removing and installing valve stem seals
  92
• 5 Inlet and exhaust valves
  95
• 5.1 Reworking valve seats
  95
• 5.2 Checking valve guides
  97
• 5.3 Checking valves
  97
• 5.4 Valve dimensions
  98
• Lubrication
  99
• 1 Sump, oil pump
  99
• 1.1 Assembly overview - sump and oil pump
  99
• 1.2 Engine oil
  101
• 1.3 Removing and installing sump
  101
• 1.4 Removing and installing oil pump
  105
• 2 Oil filter, oil pressure switch
  108
• 2.1 Checking oil pressure and oil pressure switch
  108
• Cooling
  110
• 1 Cooling system, coolant
  110
• 1.1 Coolant hose schematic diagram
  110
• 1.2 Checking cooling system for leaks
  111
• 1.3 Draining and filling coolant
  113
• 2 Coolant pump, regulation of cooling system
  117
• 2.1 Assembly overview - coolant pump, thermostat
  117
• 2.2 Assembly overview - coolant temperature sender
  118
• 2.3 Removing and installing coolant pump
  120
• 3 Radiator and radiator fan
  123
• 3.1 Assembly overview - radiator and radiator fan
  123
• 3.2 Removing and installing radiator
  127
• 3.3 Removing and installing radiator cowling with radiator fan
  131
• 3.4 Removing and installing radiator fan V7 and radiator fan 2 V177
  132
• Mixture preparation - injection
  133
• 1 Injection system
  133
• 1.1 Filling and bleeding fuel system
  133
• 2 Injectors
  136
• 2.1 Assembly overview - fuel rail with injectors
  136
• 2.2 Removing and installing injectors
  136
• 2.3 Checking injectors
  138
• 3 Air filter
  142
• 3.1 Assembly overview - air filter housing
  142
• 3.2 Removing and installing air filter housing
  143
• 4 Intake manifold
  144
• 4.1 Assembly overview - intake manifold
  144
• 4.2 Cleaning throttle valve module J338
  145
• 5 Engine control unit
  146
• 5.1 Removing and installing engine control unit J623
  146
• Exhaust system
  147
• 1 Exhaust pipes, silencers
  147
• 1.1 Assembly overview - silencers
  147
• 1.2 Removing and installing front exhaust pipe
  148
• 1.3 Removing and installing rear silencer
  149
• 1.4 Installation position of clamp
  151
• 2 Emission control
  153
• 2.1 Assembly overview - emission control
  153
• Ignition system
  155
• 1 Ignition system
  155
• 1.1 Assembly overview - ignition system
  155
• 1.2 Test data, spark plugs
  156
• 1.3 Removing and installing ignition coils with output stage
  156
• 1.4 Removing and installing engine speed sender G28
  157