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

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 Removing engine
  3
• 1.2 Securing engine to assembly stand
  7
• 1.3 Installing engine
  7
• 1.4 Assembly mountings
  10
• Crankshaft group
  12
• 1 Dismantling and assembling engine
  12
• 1.1 Part I Assembly overview - belt drive
  12
• 1.2 Part II Assembly overview - cylinder block
  14
• 1.3 Removing and installing poly V-belt
  16
• 1.4 Removing and installing valve timing housing
  17
• 2 Sealing flange and flywheel
  21
• 2.1 Assembly overview - sealing flange
  21
• 2.2 Renewing crankshaft oil seal - belt pulley end
  23
• 2.3 Poly V-belt pulley securing bolt tightening procedure
  24
• 2.4 Renewing crankshaft sealing flange - flywheel end
  27
• 2.5 Crankshaft dimensions
  34
• 3 Pistons and conrods
  36
• 3.1 Assembly overview - Pistons and conrods
  36
• 3.2 Checking piston
  37
• 3.3 Piston and cylinder dimensions
  38
• Cylinder head, valve gear
  39
• 1 Cylinder head
  39
• 1.1 Assembly overview - cylinder head
  39
• 1.2 Checking valve timing
  42
• 1.3 Adjusting valve timing
  43
• 1.4 Removing and installing timing chain and chain drive for oil pump
  47
• 1.5 Removing and installing camshaft housing
  54
• 1.6 Removing and installing cylinder head
  59
• 1.7 Checking compression
  61
• 2 Valve gear
  63
• 2.1 Assembly overview - valve gear
  63
• 2.2 Checking camshaft axial clearance
  65
• 2.3 Machining valve seats
  65
• 2.4 Checking valve guides
  67
• 2.5 Renewing valve stem seals
  67
• Lubrication
  70
• 1 Parts of lubrication system
  70
• 1.1 Engine oil
  70
• 1.2 Assembly overview - parts of lubrication system
  70
• 1.3 Removing and installing sump
  73
• 1.4 Removing and installing oil pump
  74
• 1.5 Checking oil pressure and oil pressure switch
  76
• Cooling
  79
• 1 Parts of cooling system
  79
• 1.1 Assembly overview - parts of cooling system, body side
  79
• 1.2 Assembly overview - parts of cooling system, engine side
  81
• 1.3 Coolant hose schematic diagram
  83
• 1.4 Draining and filling coolant
  84
• 1.5 Removing and installing radiator fan V7 and radiator fan 2 V177
  87
• 1.6 Removing and installing radiator
  88
• 1.7 Removing and installing coolant pump
  91
• 1.8 Checking cooling system for leaks
  92
• Fuel supply system
  95
• 1 Safety precautions
  95
• 1.1 Safety precautions when working on fuel supply system
  95
• 1.2 Releasing fuel pressure in high-pressure section
  96
• 2 Fuel tank
  98
• 2.1 Rules for cleanliness
  98
• 2.2 Assembly overview - fuel tank
  98
• 2.3 Emptying fuel tank
  100
• 2.4 Removing and installing fuel tank
  102
• 3 Repairing fuel supply system
  106
• 3.1 Rules for cleanliness
  106
• 3.2 Removing and installing fuel delivery unit
  106
• 3.3 Removing and installing fuel gauge sender G
  108
• 3.4 Checking fuel pump
  108
• 4 Electronic power control (EPC)
  117
• 4.1 Assembly overview - accelerator module
  117
• 4.2 Removing and installing accelerator pedal module
  117
• 5 Activated charcoal filter system
  120
• 5.1 Assembly overview - activated charcoal filter system
  120
• 5.2 Checking fuel tank breather
  120
• Mixture preparation - injection
  123
• 1 Injection system
  123
• 1.1 General notes on injection
  123
• 1.2 Technical data
  123
• 1.3 Assembly overview - air filter
  124
• 1.4 Removing and installing air filter
  124
• 1.5 Assembly overview - intake manifold
  126
• 1.6 Assembly overview - Fuel rail with injectors
  128
• 1.7 Removing and installing injectors
  130
• 1.8 Removing and installing high-pressure pump
  133
• 1.9 Cleaning throttle valve module J338
  137
• 2 Checking components
  139
• 2.1 Checking function of intake manifold flap
  139
• 2.2 Checking vacuum reservoir in intake manifold for leaks
  139
• 2.3 Checking intake air preheating
  140
• 3 Engine control unit J623
  141
• 3.1 Removing and installing engine control unit J623
  141
• 3.2 Removing and installing anti-theft engine control unit J623
  141
• Exhaust system
  145
• 1 Parts of exhaust system
  145
• 1.1 Assembly overview - catalytic converters and attachments
  145
• 1.2 Assembly overview - silencers with mountings
  147
• 1.3 Separating centre and rear silencers
  147
• 2 Exhaust gas recirculation system
  149
• 2.1 Assembly overview - exhaust gas recirculation system
  149
• 2.2 Removing and installing exhaust gas recirculation valve N18
  150
• Ignition system
  151
• 1 Ignition system
  151
• 1.1 General notes on ignition system
  151
• 1.2 Safety precautions
  151
• 1.3 Assembly overview - ignition system
  152
• 1.4 Removing and installing ignition coils with output stage
  153
• 1.5 Spark plug test data
  154