4 - Cyl. injection engine (1.6 l)

Chapter overview

• Technical data
  1
• 1 Technical Data
  1
• 1.1 Engine number
  1
• 1.2 Engine characteristics
  1
• Removing and installing engine
  3
• 1 Engine - remove and install
  3
• 1.1 Removal - recommendations
  6
• 1.2 Engine - fasten to assembly stand
  11
• 1.3 Installation notes
  11
• 1.4 Tightening torques
  12
• 1.5 Engine and gearbox support set - align
  13
• 1.6 Power-drive unit supports
  14
• 1.7 Additional notes and installation works in vehicles with air conditioning
  15
• Crankshaft group
  17
• 1 Engine - assembly and disassembly
  17
• 1.1 Seal lid - replace
  21
• 1.2 Poly-V belt (elastic) - remove and install
  21
• 2 Crankshaft and flywheel flanges - assembly overview
  25
• 2.1 Flywheel - remove and install
  26
• 2.2 Crankshaft seal (pulley side) - replace
  27
• 2.3 Crankshaft flange (flywheel side) with Engine speed sensor G28 rotor - replace
  29
• 3 Crankshaft - remove and install
  39
• 3.1 Identifying engine bearing shells
  40
• 3.2 Colour codes
  40
• 3.3 Crankshaft - dimensions
  40
• 4 Pistons and connecting rods - removal and installation
  42
• 4.1 Piston and cylinder - dimensions
  45
• Cylinder head, valve gear
  47
• 1 Cylinder head - assembly and disassembly
  47
• 1.1 Toothed belt semi-automatic tensioning pulley - check
  50
• 1.2 Toothed belt - remove and install, adjust
  51
• 1.3 Cylinder head - remove and install
  56
• 1.4 Compression - check
  62
• 2 Camshaft - assembly overview
  66
• 2.1 Camshaft - check axial clearance
  69
• 2.2 Valve seat - trim
  70
• 2.3 Camshaft seal - replace
  72
• 2.4 Camshaft and cylinder head cover - removal and installation
  75
• 2.5 Valve guides - check
  78
• 2.6 Valve stem sealant - replace
  79
• Lubrication
  83
• 1 Lubrication system components
  83
• 1.1 Lubricating system components - assembly overview
  83
• 1.2 Engine oil
  85
• 1.3 Crankcase - remove and install
  86
• 1.4 Oil filter - replace
  88
• 1.5 Oil pump - remove and install
  90
• 1.6 Oil pressure switch F1 - remove and install
  93
• 1.7 Oil pressure and Oil pressure switch F1 - check
  94
• Cooling
  97
• 1 Cooling system components - remove and install
  97
• 1.1 Cooling system components on the body side - assembly overview
  97
• 1.2 Cooling system components on the engine side - assembly overview
  99
• 1.3 Hose connection diagram for cooling system
  102
• 1.4 Cooling system - drainage and replenishment
  103
• 1.5 Cooling system - check air-tightness
  109
• 1.6 Radiator - remove and install
  111
• 1.7 Water pump - remove and install
  113
• Fuel supply system
  116
• 1 Fuel supply system components - removal and installation
  116
• 1.1 Fuel tank components with accessories and fuel filter - removal and installation
  116
• 1.2 Safety measures regarding work on the fuel supply systems
  119
• 1.3 Cleaning rules
  120
• 1.4 Cold start system components - remove and install
  120
• 1.5 Fuel pump (pre-supply pump) G6 - remove and install
  122
• 1.6 Fuel gauge sensor G - remove and install
  124
• 1.7 Fuel reservoir - remove and install
  124
• 1.8 Fuel pump (pre-supply pump) G6 - check
  126
• 2 Engine power electronic adjustment (electronic accelerator) - check
  135
• 2.1 Electronic accelerator system operation
  135
• 3 Activated charcoal filter system
  137
• 3.1 Operation
  137
• 3.2 Activated charcoal filter system components - repair
  137
• 3.3 Fuel tank ventilation - check
  138
• Mixture preparation - injection
  140
• 1 Injection system - repair
  140
• 1.1 General instructions regarding the injection system
  140
• 1.2 Component location
  140
• 1.3 Injection components - remove and install
  143
• 1.4 Intake manifold - remove and install
  146
• 1.5 Fuel distributor with injectors - removal and installation
  147
• 1.6 Air filter - disassembly and assembly
  147
• 1.7 Air filter - remove and install
  148
• 1.8 Safety measures
  149
• 1.9 Cleaning rules
  150
• 1.10 Technical Data
  150
• 2 Component checks
  152
• 2.1 Injection valves - check
  152
• 2.2 Residual pressure and fuel pressure regulator - check
  154
• 3 READINESS code
  159
• 3.1 Creating and Interpreting the READINESS code
  159
• 4 Engine control unit J623
  160
• 4.1 Engine control unit J623 - remove and install
  160
• 4.2 Adjust components
  161
• 4.3 Event memory in Engine control unit J623 - reference and erase
  161
• Exhaust system
  164
• 1 Exhaust system components - remove and install
  164
• 1.2 Rear muffler with supports
  166
• Glow plug system
  168
• 1 Ignition system: repair
  168
• 1.1 General instructions regarding the ignition system
  168
• 1.2 Ignition system components - remove and install
  168
• 1.3 Safety measures
  170
• 1.4 Test data, spark plugs
  170