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 Removing engine
  2
• 1.2 Installing engine
  7
• Crankshaft group
  11
• 1 Dismantling and assembling engine
  11
• 1.1 Assembly overview
  11
• 1.2 Removing and installing poly V-belt
  16
• 2 Sealing flange and flywheel or drive plate
  19
• 2.1 Assembly overview - sealing flanges
  19
• 2.2 Renewing crankshaft oil seal on pulley end
  20
• 2.3 Removing and installing sealing flange - pulley end
  22
• 2.4 Removing and installing crankshaft sealing flange - flywheel end
  25
• 2.5 Removing and installing drive plate
  29
• 3 Crankshaft
  31
• 3.1 Assembly overview - crankshaft
  31
• 3.2 Crankshaft dimensions
  33
• 4 Pistons and conrods
  34
• 4.1 Assembly overview - pistons and conrods
  34
• 4.2 Checking pistons, piston rings and cylinder bores
  36
• 4.3 Piston and cylinder dimensions
  38
• Cylinder head, valve gear
  39
• 1 Cylinder head
  39
• 1.1 Assembly overview - cylinder head
  39
• 1.2 Removing and installing cylinder head
  42
• 1.3 Removing, installing and tensioning toothed belts
  46
• 1.4 Checking semi-automatic toothed belt tensioning roller
  53
• 1.5 Checking compression
  53
• 2 Valve gear
  56
• 2.1 Assembly overview - valve gear
  56
• 2.2 Valve dimensions
  58
• 2.3 Reworking valve seats
  58
• 2.4 Checking valve guides
  59
• 2.5 Renewing camshaft oil seal
  60
• 2.6 Removing and installing camshaft
  63
• 2.7 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
  71
• 1.3 Removing and installing sump
  75
• 1.4 Removing and installing oil pump
  76
• 1.5 Checking oil pressure and oil pressure switch
  77
• Cooling
  79
• 1 Parts of cooling system
  79
• 1.1 Assembly overview - parts of cooling system, engine side
  79
• 1.2 Assembly overview - parts of cooling system, body side (radiator with two radiator fans)
  81
• 1.4 Coolant hose schematic diagram
  83
• 1.5 Draining and filling coolant
  84
• 1.6 Removing and installing coolant pump
  87
• 1.7 Removing and installing thermostat
  90
• 1.8 Removing and installing radiator fan V7 and radiator fan 2 V177
  92
• 1.9 Removing and installing radiator
  93
• 1.10 Checking cooling system for leaks
  95
• Fuel supply system
  98
• 1 Fuel tank
  98
• 1.1 Safety precautions when working on fuel supply system
  98
• 1.2 Rules for cleanliness
  99
• 1.3 Assembly overview - fuel tank
  99
• 1.4 Emptying fuel tank
  101
• 1.5 Removing and installing fuel tank
  107
• 2 Repairing fuel supply
  110
• 2.1 Safety precautions when working on fuel supply system
  110
• 2.2 Rules for cleanliness
  111
• 2.3 Removing and installing fuel delivery unit
  111
• 2.4 Removing and installing fuel gauge sender G (up to November 2006)
  114
• 2.5 Removing and installing fuel gauge sender G from November 2006
  114
• 2.6 Assembly overview - fuel filter with attachments
  115
• 2.7 Removing and installing fuel filter
  116
• 2.8 Checking fuel pump
  117
• 2.9 Bleeding fuel system
  130
• 3 Electronic power control (EPC)
  133
• 3.1 Function of EPC system
  133
• 3.2 Assembly overview - accelerator pedal module
  133
• 3.3 Removing and installing accelerator pedal module
  134
• 4 Activated charcoal filter system
  137
• 4.1 Function
  137
• 4.2 Checking fuel tank breather
  137
• Mixture preparation - injection
  139
• 1 Injection system
  139
• 1.1 General notes on injection
  139
• 1.2 Safety precautions
  140
• 1.3 Rules for cleanliness
  140
• 1.4 Technical data
  141
• 1.5 Assembly overview - intake manifold with attachments, engine code BGU
  141
• 1.6 Assembly overview - intake manifold with attachments, engine codes BSE, BSF
  143
• 1.7 Assembly overview - fuel rail with injectors
  144
• 1.8 Assembly overview - air filter with attachments
  145
• 1.9 Removing and installing lower part of intake manifold, engine code BGU
  145
• 1.10 Removing and installing lower part of intake manifold, engine codes BSE, BSF
  148
• 1.11 Removing and installing complete intake manifold, engine code BGU
  149
• 1.12 Removing and installing complete intake manifold, engine codes BSE, BSF
  154
• 1.13 Removing and installing injectors
  157
• 2 Checking components
  159
• 2.1 Checking injectors for leaks and quantity injected
  159
• 2.2 Checking fuel pressure regulator and holding pressure
  165
• 2.3 Checking intake manifold change-over
  168
• 3 Engine control unit
  171
• 3.1 Removing and installing engine control unit
  171
• 3.2 Removing and installing anti-theft engine control unit
  172
• Exhaust system
  174
• 1 Parts of the exhaust system
  174
• 1.1 Assembly overview - exhaust system
  174
• 1.2 Separating centre and rear silencers
  177
• 1.3 Removing and installing front exhaust pipe with catalytic converter
  178
• 1.4 Removing and installing exhaust manifold
  179
• 1.5 Aligning exhaust system free of stress
  181
• 1.6 Removing and installing Lambda probe G39
  181
• 1.7 Removing and installing Lambda probe after catalytic converter G130
  183
• 2 Exhaust gas recirculation system, engine code BGU
  185
• 2.1 Assembly overview - exhaust gas recirculation system
  185
• 3 Secondary air system, engine codes BGU, BSE
  187
• 3.1 Function
  187
• 3.2 Assembly overview - secondary air system, engine code BGU
  187
• 3.3 Assembly overview - secondary air system, engine code BSE
  189
• 3.4 Checking combination valve
  189
• Ignition system
  191
• 1 Repairing ignition system
  191
• 1.1 General notes on ignition system
  191
• 1.2 Safety precautions
  191
• 1.3 Assembly overview - ignition system
  191
• 1.4 Test data, spark plugs
  192