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
  3
• 1 Removing and installing engine
  3
• 1.1 Removing engine
  4
• 1.2 Securing engine to assembly stand
  8
• 1.3 Installing engine
  10
• 1.4 Checking and adjusting assembly mountings
  13
• 1.5 Assembly mountings- specified torques
  16
• Crankshaft group
  17
• 1 Dismantling and assembling engine
  17
• 1.1 Assembly overview
  17
• 1.2 Removing and installing poly V-belt
  22
• 2 Removing and installing sealing flanges and flywheel or drive plate
  25
• 2.1 Assembly overview - sealing flange
  25
• 2.2 Renewing crankshaft oil seal - pulley end
  26
• 2.3 Removing and installing sealing flange - pulley end
  29
• 2.4 Removing and installing sealing flange on gearbox side
  32
• 2.5 Removing and installing flywheel
  35
• 2.6 Removing and installing drive plate
  35
• 3 Crankshaft
  38
• 3.1 Assembly overview - crankshaft
  38
• 3.2 Crankshaft dimensions
  40
• 3.3 Pulling needle bearing out of and driving into crankshaft
  41
• 4 Pistons and conrods
  43
• 4.1 Assembly overview - pistons and conrods
  43
• 4.2 Checking pistons, piston rings and cylinder bores
  45
• 4.3 Piston and cylinder dimensions
  46
• Cylinder head, valve gear
  47
• 1 Cylinder head
  47
• 1.1 Assembly overview - cylinder head
  47
• 1.2 Removing and installing toothed belt
  50
• 1.3 Checking semi-automatic toothed belt tensioning roller
  55
• 1.4 Removing and installing cylinder head
  55
• 1.5 Checking compression
  60
• 2 Valve gear
  63
• 2.1 Assembly overview - valve gear
  63
• 2.2 Valve dimensions
  65
• 2.3 Reworking valve seats
  65
• 2.4 Checking valve guides
  66
• 2.5 Renewing camshaft oil seal
  67
• 2.6 Removing and installing camshaft
  70
• 2.7 Renewing valve stem seals
  75
• 2.8 Checking supporting elements with hydraulic clearance compensation
  78
• Lubrication
  79
• 1 Parts of lubrication system
  79
• 1.1 Engine oil
  79
• 1.2 Assembly overview - parts of lubrication system
  80
• 1.3 Removing and installing oil sump
  83
• 1.4 Removing and installing oil pump
  85
• 1.5 Checking oil pressure and oil pressure switch
  85
• Cooling
  88
• 1 Parts of cooling system
  88
• 1.5 Coolant hose schematic diagram
  93
• 1.6 Coolant hose schematic diagram - engine codes CCSA, CMXA
  96
• 1.7 Draining and filling coolant
  97
• 1.8 Removing and installing coolant pump
  101
• 1.9 Removing and installing thermostat
  103
• 1.10 Removing and installing radiator fan V7 and radiator fan 2 V177
  105
• 1.11 Removing and installing radiator
  107
• 1.12 Checking cooling system for leaks
  109
• 2 Engine preheater
  112
• 2.1 Assembly overview - engine preheating, engine codes CCSA, CMXA
  112
• Fuel supply system
  113
• 1 Fuel tank
  113
• 1.1 Safety precautions when working on fuel supply system
  113
• 1.2 Rules for cleanliness
  113
• 1.3 Assembly overview - fuel tank
  114
• 1.4 Emptying fuel tank
  116
• 1.5 Removing and installing fuel tank
  120
• 2 Repairing fuel supply system
  123
• 2.1 Safety precautions when working on fuel supply system
  123
• 2.2 Rules for cleanliness
  124
• 2.3 Removing and installing fuel delivery unit
  124
• 2.4 Removing and installing fuel gauge sender G
  126
• 2.5 Assembly overview - fuel filter with attachments
  128
• 2.6 Removing and installing fuel filter
  129
• 2.7 Checking fuel pump
  130
• 2.8 Bleeding fuel system
  140
• 3 Electronic power control (EPC)
  143
• 3.1 Function of EPC system
  143
• 3.2 Assembly overview - accelerator module
  143
• 3.3 Removing and installing accelerator module
  144
• 4 Activated charcoal filter system
  147
• 4.1 Function
  147
• 4.2 Assembly overview - activated charcoal filter system
  147
• 4.3 Checking fuel tank breather
  148
• Mixture preparation - injection
  150
• 1 Injection system
  150
• 1.1 General notes on injection
  150
• 1.2 Safety precautions
  151
• 1.3 Rules for cleanliness
  151
• 1.4 Technical data
  152
• 1.5 Overview of fitting locations
  152
• 1.6 Assembly overview - intake manifold with attachments
  155
• 1.7 Assembly overview - fuel rail with injectors
  156
• 1.8 Assembly overview - air filter with attachments
  157
• 1.9 Removing and installing lower part of intake manifold
  157
• 1.10 Removing and installing complete intake manifold
  159
• 1.11 Removing and installing injectors
  162
• 2 Checking components
  164
• 2.1 Checking injectors for leaks and quantity injected
  164
• 2.2 Checking fuel pressure regulator and holding pressure
  168
• 2.3 Checking intake manifold change-over
  172
• 3 Engine control unit
  174
• 3.1 Reading and erasing engine control unit fault memory
  174
• 3.2 Removing and installing engine control unit
  175
• Exhaust system
  179
• 1 Exhaust system (engine codes BSE, BSF, CCSA)
  179
• 1.1 Assembly overview - exhaust system
  181
• 1.2 Removing and installing exhaust manifold
  182
• 1.3 Removing and installing front exhaust pipe with catalytic converter
  183
• 1.4 Separating and joining front and rear silencers
  185
• 1.5 Aligning exhaust system free of stress
  187
• 1.6 Removing and installing Lambda probe G39
  188
• 1.7 Removing and installing Lambda probe after catalytic converter G130
  189
• 2 Exhaust system, engine code CMXA
  191
• 2.2 Assembly overview - exhaust system
  193
• 2.3 Separating and joining front and rear silencers
  193
• 2.4 Removing and installing front exhaust pipe with catalytic converter
  195
• 2.5 Removing and installing exhaust manifold
  197
• 2.6 Aligning exhaust system free of stress
  198
• 2.7 Removing and installing Lambda probe G39
  199
• 2.8 Removing and installing Lambda probe after catalytic converter G130
  201
• 3 Secondary air system
  203
• 3.1 Function
  203
• 3.2 Assembly overview - secondary air system
  203
• 3.3 Checking combination valve
  204
• Ignition system
  206
• 1 Repairing ignition system
  206
• 1.1 General notes on ignition system
  206
• 1.2 Safety precautions
  206
• 1.3 Assembly overview - ignition system
  207
• 1.4 Test data, spark plugs
  208