4-cylinder injection engine (1.6 l roller rocker finger)

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 assembly work 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 on 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
  33
• Cylinder head, valve gear
  34
• 1 Cylinder head
  34
• 1.1 Removing and installing cylinder head
  36
• 1.2 Removing, installing and tensioning toothed belt
  39
• 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 oil 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 Electronically regulated cooling system
  68
• 1.2 Parts of cooling system, body side
  69
• 1.3 Parts of cooling system, engine side
  71
• 1.4 Coolant hose schematic diagram
  72
• 1.5 Draining and filling coolant
  73
• 1.6 Removing and installing radiator
  75
• 1.7 Removing and installing coolant pump
  77
• 1.8 Dismantling and assembling coolant distribution housing
  78
• 1.9 Checking map-controlled engine cooling thermostat
  79
• Fuel supply system
  81
• 1 Removing and installing parts of fuel supply system
  81
• 1.1 Removing and installing fuel tank with attachments and fuel filter
  81
• 1.2 Safety precautions when working on fuel supply system
  84
• 1.3 Rules for cleanliness
  85
• 1.4 Removing and installing fuel delivery unit
  85
• 1.5 Removing and installing fuel gauge sender G
  87
• 1.6 Removing and installing fuel tank
  87
• 1.7 Checking fuel pump
  88
• 2 Accelerator mechanism
  95
• 2.1 Repairing accelerator mechanism
  95
• 2.2 Function of EPC system
  95
• 3 Activated charcoal filter system
  97
• 3.1 Function
  97
• 3.2 Repairing parts of activated charcoal filter system
  97
• 3.3 Checking fuel tank breather
  98
• Mixture preparation - injection
  100
• 1 Repairing injection system
  100
• 1.1 General notes on injection
  100
• 1.2 Dismantling and assembling upper part of intake manifold
  100
• 1.3 Dismantling and assembling lower part of intake manifold
  102
• 1.4 Dismantling and assembling fuel rail with injectors
  103
• 1.5 Dismantling and assembling air filter
  104
• 1.6 Safety precautions
  104
• 1.7 Rules for cleanliness
  106
• 1.8 Technical data
  106
• 2 Checking components
  107
• 2.1 Checking injectors for leaks and injection rate
  107
• 2.2 Checking fuel pressure regulator and holding pressure
  109
• 2.3 Checking intake manifold change-over
  112
• 3 Engine control unit
  114
• 3.1 Renewing engine control unit
  114
• 3.2 Adapting functions and components
  114
• 3.3 Reading and erasing engine control unit fault memory
  115
• Exhaust system
  117
• 1 Removing and installing parts of exhaust system
  117
• 1.2 Silencer with mountings
  120
• 2 Secondary air system
  122
• 2.1 Function
  122
• 2.2 Removing and installing parts of secondary air system
  122
• 2.3 Checking combination valve
  123
• 3 Exhaust gas recirculation system
  125
• 3.1 Repairing parts of exhaust gas recirculation system
  125
• Ignition system
  126
• 1 Repairing ignition system
  126
• 1.1 General notes on ignition system
  126
• 1.2 Removing and installing parts of ignition system
  126
• 1.3 Safety precautions
  127
• 1.4 Test data, spark plugs
  128