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

Chapter overview

• Technical data
  1
• 1 Identification
  1
• 1.1 Engine number/engine data
  1
• 2 Safety information
  2
• 2.1 Safety precautions when working on the cooling system
  2
• 2.2 Safety regulations for working on fuel supply
  3
• 2.3 Safety precautions when working on ignition system
  4
• 2.5 Safety precautions when working on injection system
  4
• 3 Technical data
  6
• 3.1 Technical data - injection system
  6
• 4 Repair instructions
  7
• 4.1 Rules for cleanliness when working on fuel supply system/injection system
  7
• 4.2 General notes on ignition system
  7
• 4.3 General notes on injection
  7
• 4.4 Foreign objects in engine
  8
• Removing and installing engine
  9
• 1 Removing and installing engine
  9
• 1.1 Removing engine
  9
• 1.2 Securing engine on engine and gearbox support
  13
• 1.3 Installing engine
  14
• 2 Assembly mountings
  16
• 2.1 Overview - assembly mountings
  16
• Crankshaft group
  18
• 1 Cylinder block (pulley end)
  18
• 1.1 Assembly overview - poly V-belt drive
  18
• 1.2 Assembly overview - cylinder block
  22
• 1.3 Removing and installing poly-V belt
  23
• 1.4 Renewing crankshaft oil seal - belt pulley end
  25
• 1.5 Removing and installing sealing flange on pulley end
  27
• 2 Cylinder block, gearbox end
  31
• 2.1 Assembly overview - cylinder block, gearbox end
  31
• 2.2 Removing and installing sealing flange on gearbox side
  32
• 3 Crankshaft
  34
• 3.1 Assembly overview - crankshaft
  34
• 3.2 Allocation of main bearing shells
  35
• 3.3 Removing and installing sender wheel
  36
• 3.4 Crankshaft dimensions
  36
• 4 Pistons and conrods
  37
• 4.1 Assembly overview - pistons and conrods
  37
• 4.2 Bearing shells - installation position
  38
• 4.3 Checking pistons and cylinder bores
  38
• 4.4 Piston and cylinder dimensions
  40
• Cylinder head, valve gear
  41
• 1 Cylinder head
  41
• 1.1 Assembly overview - cylinder head
  41
• 1.2 Removing and installing cylinder head
  43
• 1.3 Checking compression
  48
• 2 Toothed belt drive
  51
• 2.1 Assembly overview - toothed belt drive
  51
• 2.2 Removing and installing toothed belt
  53
• 2.3 Checking semi-automatic toothed belt tensioner
  59
• 2.4 Removing and installing toothed belt guard
  59
• 3 Valve gear
  60
• 3.1 Assembly overview - valve gear
  60
• 3.2 Removing and installing camshaft oil seal
  62
• 3.3 Removing and installing camshaft
  64
• 3.4 Measuring axial play of camshaft
  69
• 3.5 Removing and installing valve stem seals
  69
• 3.6 Checking hydraulic compensation elements
  71
• 4 Inlet and exhaust valves
  73
• 4.1 Reworking valve seats
  73
• 4.2 Checking valve guides
  74
• 4.3 Valve dimensions
  75
• Lubrication
  76
• 1 Sump, oil pump
  76
• 1.1 Assembly overview - sump/oil pump
  76
• 1.2 Removing and installing oil sump
  79
• 1.3 Removing and installing oil pump
  81
• 1.4 Engine oil:
  81
• 2 Oil filter, oil pressure switch
  83
• 2.1 Assembly overview - oil filter/oil pressure switch
  83
• 2.2 Checking oil pressure and oil pressure switch
  85
• 2.3 Measuring oil consumption
  86
• Cooling
  88
• 1 Cooling system/coolant
  88
• 1.1 Connection diagram - coolant hoses
  88
• 1.2 Draining and adding coolant
  89
• 1.3 Checking cooling system for leaks
  96
• 2 Coolant pump, regulation of cooling system
  98
• 2.1 Assembly overview - coolant pump, thermostat
  98
• 2.2 Removing and installing coolant pump
  99
• 2.3 Removing and installing thermostat
  101
• 3 Radiator, radiator fan
  103
• 3.1 Assembly overview - radiator/radiator fan
  103
• 3.2 Removing and installing radiator
  104
• 3.3 Removing and installing radiator fan V7 and radiator fan 2 V177
  106
• Mixture preparation - injection
  108
• 1 Injection system
  108
• 1.1 Bleeding fuel system
  108
• 2 Injectors
  111
• 2.1 Assembly overview - fuel rail with injectors
  111
• 2.2 Removing and installing injectors
  111
• 2.3 Checking injectors
  112
• 3 Senders and sensors
  117
• 3.1 Checking fuel pressure regulator and holding pressure
  117
• 3.2 Checking fuel pressure regulator and holding pressure
  119
• 4 Intake manifold
  122
• 4.1 Assembly overview - intake manifold
  122
• 4.2 Assembly overview - intake manifold
  124
• 4.3 Removing and installing lower part of intake manifold
  125
• 4.4 Removing and installing lower part of intake manifold
  127
• 4.5 Removing and installing intake manifold
  129
• 4.6 Removing and installing intake manifold
  133
• 4.7 Checking intake manifold change-over
  136
• 5 Air filter
  138
• 5.1 Assembly overview - air filter housing
  138
• 6 Engine (motor) control unit
  139
• 6.1 Removing and installing engine control unit J623
  139
• 6.2 Removing and installing anti-theft engine control unit J623
  140
• Exhaust system
  142
• 1 Exhaust pipes and silencers
  142
• 1.1 Assembly overview - silencers
  142
• 1.2 Separating exhaust pipes from silencers
  142
• 1.3 Installation position of clamp
  144
• 1.4 Check exhaust system for leaks
  144
• 1.5 Aligning exhaust system free of stress
  144
• 2 Exhaust gas cleaning
  146
• 2.1 Assembly overview - emission control
  146
• 2.2 Removing and installing front exhaust pipe with catalytic converter
  147
• 3 Exhaust gas recirculation
  149
• 3.1 Assembly overview - exhaust gas recirculation
  149
• 4 Secondary air system
  151
• 4.1 Assembly overview - secondary air system
  151
• 4.2 Assembly overview - secondary air system
  152
• 4.3 Function of secondary air system
  153
• 4.4 Checking combination valve
  153
• 5 Exhaust manifold
  155
• 5.1 Removing and installing exhaust manifold
  155
• Ignition system
  157
• 1 Ignition system
  157
• 1.1 Assembly overview - ignition system
  157
• 1.2 Test data, spark plugs
  158