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 engine stand
  7
• 1.3 Installing engine
  7
• 1.4 Tightening torques
  8
• 1.5 Assembly mountings
  9
• 1.6 Notes on repairs to air conditioning system
  9
• Crankshaft group
  11
• 1 Dismantling and assembling engine
  11
• 1.1 Part I: Assembly overview - belt drive
  12
• 1.2 Part II: Assembly overview - cylinder block
  13
• 1.3 Removing and installing poly V-belt
  15
• 1.4 Removing and installing valve timing housing
  16
• 2 Removing and installing sealing flanges and flywheel/drive plate
  19
• 2.1 Assembly overview
  19
• 2.2 Renewing crankshaft oil seal - pulley end
  21
• 2.3 Poly V-belt pulley securing bolt tightening procedure
  22
• 2.4 Renewing crankshaft sealing flange - flywheel end, vehicles with manual gearbox
  26
• 2.6 Crankshaft dimensions
  39
• 3 Dismantling and assembling pistons and conrods
  41
• 3.1 Assembly overview
  41
• 3.2 Checking piston
  42
• 3.3 Piston and cylinder dimensions
  43
• Cylinder head, valve gear
  44
• 1 Cylinder head
  44
• 1.1 Assembly overview
  45
• 1.2 Checking valve timing
  47
• 1.3 Adjusting valve timing
  49
• 1.4 Removing and installing camshaft housing
  53
• 1.5 Removing and installing cylinder head
  56
• 1.6 Checking compression
  59
• 2 Repairing valve gear
  61
• 2.1 Assembly overview
  61
• 2.2 Checking camshaft axial clearance
  63
• 2.3 Reworking valve seats
  63
• 2.4 Checking valve guides
  65
• 2.5 Renewing valve shaft seals
  66
• Lubrication
  68
• 1 Removing and installing parts of lubrication system
  68
• 1.1 Engine oil
  68
• 1.2 Assembly overview
  69
• 1.3 Removing and installing sump
  70
• 1.4 Removing and installing oil pump
  72
• 1.5 Checking oil pressure and oil pressure switch
  75
• Cooling
  77
• 1 Removing and installing parts of cooling system
  77
• 1.1 Assembly overview - parts of cooling system - body side
  78
• 1.2 Assembly overview - parts of cooling system - engine side
  79
• 1.3 Coolant hose schematic diagram
  81
• 1.4 Draining and filling cooling system
  82
• 1.5 Removing and installing radiator
  84
• 1.6 Removing and installing coolant pump
  86
• Fuel supply system
  88
• 1 Fuel tank
  88
• 1.1 Safety precautions when working on fuel supply system
  88
• 1.2 Rules for cleanliness
  88
• 1.3 Assembly overview - fuel tank
  89
• 1.4 Emptying fuel tank
  90
• 1.5 Removing and installing fuel tank
  92
• 2 Repairing fuel supply system
  95
• 2.1 Safety precautions when working on fuel supply system
  95
• 2.2 Rules for cleanliness
  95
• 2.3 Removing and installing fuel delivery unit
  96
• 2.4 Removing and installing fuel gauge sender G
  99
• 2.5 Checking fuel pump
  99
• 2.6 Removing and installing high pressure pump
  105
• 3 Repairing electronic power control (EPC)
  110
• 3.1 Function of EPC system
  110
• 3.2 Assembly overview
  111
• 3.3 Removing and installing accelerator module
  111
• 4 Activated charcoal filter system
  113
• 4.1 Function
  113
• 4.2 Assembly overview
  114
• 4.3 Checking fuel tank breather system
  114
• Mixture preparation - injection
  116
• 1 Repairing injection system
  116
• 1.1 Assembly overview - intake manifold
  117
• 1.2 Assembly overview - fuel rail with injectors
  119
• 1.3 Checking vacuum reservoir in intake manifold for leaks
  120
• 1.4 Assembly overview - air filter
  121
• 1.5 Removing and installing air filter
  122
• 1.6 Cleaning throttle valve module J338
  123
• 1.7 Removing and installing injectors
  124
• 1.8 Safety precautions
  127
• 1.9 Rules for cleanliness
  129
• 1.10 Technical data
  129
• 2 Checking components
  130
• 2.1 Checking intake air preheating
  130
• 3 Engine control unit
  131
• 3.1 Removing and installing engine control unit
  131
• 3.2 Removing and installing anti-theft engine control unit
  132
• Exhaust system
  136
• 1 Removing and installing parts of exhaust system
  136
• 1.1 Assembly overview - catalytic converters and attachments
  136
• 1.2 Assembly overview - silencer with mountings
  138
• 2 Exhaust gas recirculation system
  140
• 2.1 Exhaust gas recirculation system - exploded view
  140
• 2.2 Removing and installing exhaust gas recirculation valve N18
  141
• Ignition system
  143
• 1 Repairing ignition system
  143
• 1.1 Assembly overview - ignition system
  144
• 1.2 Removing and installing ignition coils with output stages
  144
• 1.3 Safety precautions
  145
• 1.4 Test data, spark plugs
  146