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
  3
• 1.2 Installing engine
  8
• Crankshaft group
  11
• 1 Dismantling and assembling engine
  11
• 1.1 Assembly overview
  11
• 1.2 Removing and installing poly V-belt
  17
• 2 Sealing flanges and flywheel
  19
• 2.1 Assembly overview - sealing flange
  19
• 2.2 Renewing crankshaft oil seal - pulley end
  20
• 2.3 Removing and installing sealing flange - pulley end
  22
• 2.4 Removing and installing crankshaft sealing flange - flywheel end
  25
• 3 Removing and installing crankshaft
  30
• 3.1 Assembly overview - crankshaft
  30
• 3.2 Crankshaft dimensions
  32
• 4 Dismantling and assembling pistons and conrods
  33
• 4.1 Assembly overview - pistons and conrods
  33
• 4.2 Separating new conrod
  34
• 4.3 Checking pistons, piston rings and cylinder bores
  34
• 4.4 Piston and cylinder dimensions
  36
• Cylinder head, valve gear
  37
• 1 Cylinder head
  37
• 1.1 Assembly overview - cylinder head
  37
• 1.2 Removing and installing cylinder head
  40
• 1.3 Removing, installing and tensioning toothed belt
  44
• 1.4 Checking semi-automatic toothed belt tensioning roller
  50
• 1.5 Checking compression
  51
• 2 Valve gear
  53
• 2.1 Assembly overview - valve gear
  53
• 2.2 Valve dimensions
  55
• 2.3 Reworking valve seats
  55
• 2.4 Checking valve guides
  57
• 2.5 Renewing camshaft oil seal
  57
• 2.6 Removing and installing camshaft
  60
• 2.7 Renewing valve stem seals
  64
• Lubrication
  67
• 1 Parts of lubrication system
  67
• 1.1 Engine oil
  67
• 1.2 Assembly overview - parts of lubrication system
  67
• 1.3 Removing and installing sump
  70
• 1.4 Removing and installing oil pump
  71
• 1.5 Checking oil pressure and oil pressure switch
  72
• Cooling
  74
• 1 Removing and installing parts of cooling system
  74
• 1.1 Assembly overview - parts of cooling system, engine side
  74
• 1.2 Assembly overview - parts of cooling system, body side (radiator with two radiator fans)
  76
• 1.4 Coolant hose schematic diagram
  78
• 1.5 Draining and filling coolant
  79
• 1.6 Removing and installing radiator
  82
• 1.7 Removing and installing coolant pump
  85
• 1.8 Removing and installing thermostat
  87
• 1.9 Removing and installing radiator fan V7 and radiator fan 2 V177
  89
• 1.10 Checking cooling system for leaks
  90
• Fuel supply system
  93
• 1 Fuel tank
  93
• 1.1 Safety precautions when working on fuel supply system
  93
• 1.2 Rules for cleanliness
  93
• 1.3 Assembly overview - fuel tank
  94
• 1.4 Emptying fuel tank
  95
• 1.5 Removing and installing fuel tank
  99
• 2 Repairing fuel supply system
  103
• 2.1 Safety precautions when working on fuel supply system
  103
• 2.2 Rules for cleanliness
  104
• 2.3 Removing and installing fuel delivery unit
  104
• 2.4 Removing and installing fuel gauge sender G
  107
• 2.5 Checking fuel pump
  108
• 2.6 Bleeding fuel system
  116
• 3 Electronic power control (EPC)
  120
• 3.1 Function of EPC system
  120
• 3.2 Assembly overview - accelerator module
  120
• 3.3 Removing and installing accelerator module
  121
• 4 Activated charcoal filter system
  124
• 4.1 Function
  124
• 4.2 Assembly overview - activated charcoal filter system
  124
• 4.3 Checking fuel tank breather
  125
• Mixture preparation - injection
  127
• 1 Repairing injection system
  127
• 1.1 General notes on injection
  127
• 1.2 Safety precautions
  128
• 1.3 Rules for cleanliness
  128
• 1.4 Technical data
  129
• 1.5 Assembly overview - intake manifold with attachments
  129
• 1.6 Assembly overview - fuel rail with injectors
  131
• 1.7 Assembly overview - air filter with attachments
  132
• 1.8 Removing and installing lower part of intake manifold
  132
• 1.9 Removing and installing complete intake manifold
  134
• 1.10 Removing and installing injectors
  137
• 2 Checking components
  139
• 2.1 Checking injectors for leaks and quantity injected
  139
• 2.2 Checking intake manifold change-over
  143
• 3 Engine control unit
  145
• 3.1 Removing and installing engine control unit
  145
• 3.2 Removing and installing anti-theft engine control unit
  146
• Exhaust system
  150
• 1 Removing and installing parts of exhaust system
  150
• 1.1 Assembly overview - exhaust system
  150
• 1.2 Separating centre and rear silencers
  152
• 1.3 Removing and installing front exhaust pipe with catalytic converter
  153
• 1.4 Removing and installing exhaust manifold
  155
• 2 Secondary air system
  156
• 2.1 Function
  156
• 2.2 Assembly overview - secondary air system, engine code BSE
  156
• 2.3 Checking combination valve
  157
• Ignition system
  159
• 1 Repairing ignition system
  159
• 1.1 General notes on ignition system
  159
• 1.2 Safety precautions
  159
• 1.3 Assembly overview - ignition system
  159
• 1.4 Test data, spark plugs
  160