4-cylinder injection engine (1.6 l engine, roller rocker fingers), Mechanics

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 Notes on removing
  3
• 1.2 Securing engine to assembly stand
  7
• 1.3 Notes on installing
  8
• 1.4 Assembly mountings
  10
• 1.5 Additional information and removal instructions for vehicles with air conditioner
  11
• Crankshaft group
  13
• 1 Dismantling and assembling engine
  13
• 1.1 Assembly overview
  13
• 1.2 Removing and installing poly V-belt
  16
• 2 Removing and installing sealing flange and pressure plate/drive plate
  19
• 2.1 Renewing crankshaft oil seal - belt pulley end
  20
• 2.2 Removing and installing front sealing flange
  22
• 2.3 Removing and installing drive plate
  25
• 3 Removing and installing crankshaft
  27
• 3.1 Crankshaft dimensions
  28
• 4 Dismantling and assembling pistons and conrods
  30
• 4.1 Checking pistons, piston rings and cylinder bores
  31
• 4.2 Piston and cylinder dimensions
  32
• Cylinder head, valve gear
  33
• 1 Cylinder head
  33
• 1.1 Removing and installing cylinder head
  35
• 1.2 Removing, installing and tensioning toothed belt
  38
• 1.3 Checking semi-automatic toothed belt tensioning roller
  43
• 1.4 Checking compression
  44
• 2 Repairing valve gear
  46
• 2.1 Reworking valve seats
  48
• 2.2 Renewing camshaft oil seal
  50
• 2.3 Removing and installing camshaft
  53
• 2.4 Checking valve guides
  56
• 2.5 Renewing valve stem seals
  57
• Lubrication
  60
• 1 Removing and installing parts of lubrication system
  60
• 1.1 Engine oil
  60
• 1.2 Assembly overview - parts of lubrication system
  60
• 1.3 Assembly overview - oil filter bracket
  62
• 1.4 Removing and installing sump
  63
• 1.5 Checking oil pressure and oil pressure switch
  65
• Cooling
  68
• 1 Removing and installing parts of cooling system
  68
• 1.1 Parts of cooling system - body side
  68
• 1.2 Parts of cooling system - engine side
  71
• 1.3 Coolant hose schematic diagram
  72
• 1.4 Draining and filling coolant
  73
• 1.5 Removing and installing radiator
  75
• 1.6 Removing and installing coolant pump
  77
• 1.7 Electronically controlled cooling system
  78
• 1.8 Dismantling and assembling coolant distribution housing
  80
• 1.9 Checking map-controlled engine cooling thermostat F265
  81
• Fuel supply system
  84
• 1 Removing and installing parts of fuel supply system
  84
• 1.1 Removing and installing fuel tank with attachments and fuel filter
  84
• 1.2 Safety precautions when working on fuel supply system
  87
• 1.3 Rules for cleanliness
  87
• 1.4 Removing and installing fuel delivery unit
  88
• 1.5 Removing and installing fuel gauge sender G
  89
• 1.6 Removing and installing fuel tank
  89
• 1.7 Crash fuel shut-off
  91
• 1.8 Checking fuel pump
  91
• 2 Checking electronic power control (EPC)
  98
• 2.1 Function of EPC system
  98
• 2.2 Checking accelerator pedal position sender
  99
• 3 Activated charcoal filter system
  103
• 3.1 Function
  103
• 3.2 Repairing parts of the activated charcoal filter system
  103
• 3.3 Checking active charcoal filter system solenoid valve 1 N80
  104
• 3.4 Checking fuel tank breather system
  106
• Exhaust system
  108
• 1 Removing and installing parts of exhaust system
  108
• 1.2 Silencer with mountings
  110
• 1.3 Checking catalytic converter
  111
• 2 Secondary air system
  114
• 2.1 Function
  114
• 2.2 Removing and installing parts of secondary air system
  114
• 2.3 Checking secondary air system
  116
• 2.4 Checking secondary air pump motor V101
  118
• 3 Exhaust gas recirculation system
  120
• 3.1 Repairing parts of exhaust gas recirculation system
  120
• 3.2 Checking exhaust gas recirculation system
  121
• 3.3 Checking exhaust gas recirculation potentiometer G212
  122