4 Cylinder Fuel injection Engine Mechanics (1.6L & 1.4L), 2004▸

Chapter overview

• Technical data Materials
  1
• 1 Technical data
  1
• 1.1 Engine number
  1
• 1.2 Engine data
  1
• Self-diagnosis, Electrical check
  2
• 1 Self diagnosis
  2
• Engine assembly
  3
• 1 Removing and installing engine
  3
• 1.1 Removing
  3
• 1.2 Detaching engine from gearbox
  5
• 1.3 Installing
  5
• 1.4 Tightening torques:
  6
• Crankshaft group
  7
• 1 Engine
  7
• 1.1 Exploded view of engine
  7
• 1.2 Removing and installing V-belt
  11
• 1.3 Adjusting alternator V-belt tension
  12
• 2 Sealing flange and pressure plate
  13
• 2.1 Exploded view of sealing flange and pressure plate
  13
• 2.2 Removing and installing crankshaft oil seal pulley end
  14
• 3 Crankshaft
  16
• 3.1 Exploded view of crankshaft assembly
  16
• 3.2 Crankshaft dimensions
  17
• 4 Pistons and conrods
  18
• 4.1 Exploded view of piston and conrod
  18
• 4.2 Checking pistons
  19
• Cylinder head, Valve gear
  21
• 1 Cylinder head
  21
• 1.1 Exploded view of cylinder head
  21
• 1.2 Removing and installing toothed belt
  22
• 1.3 Checking and adjusting valve timing
  23
• 1.4 Removing and installing cylinder head
  25
• 1.5 Checking cylinder head for distortion
  27
• 1.6 Checking compressions
  27
• 2 Servicing valve gear
  28
• 2.1 Exploded view of valve gear
  28
• 2.2 Checking components of valve gear
  29
• 2.3 Reworking valve seats
  31
• 2.4 Removing and installing camshaft oil seal
  33
• 2.5 Removing and installing camshaft
  34
• 2.6 Checking hydraulic lifters
  36
• 2.7 Checking valve guides
  37
• 2.8 Renewing valve guides
  37
• 2.9 Renewing valve stem seals (with cylinder head fitted)
  38
• Lubrication
  41
• 1 Lubrication system
  41
• 1.1 Exploded view of lubrication system
  41
• 1.2 Oil specifications and capacities
  42
• 1.3 Checking oil pump backlash
  43
• 1.4 Checking oil pump axial clearance
  43
• 1.5 Marking on oil dipstick
  43
• 1.6 Checking oil pressure and oil pressure switch
  43
• Cooling system
  46
• 1 Removing and installing parts of cooling system
  46
• 1.1 Exploded view of cooling system - body side
  46
• 1.2 Exploded view of cooling system - engine side
  48
• 1.3 Exploded view of coolant pump
  50
• 1.4 Removing and installing coolant pump
  51
• 1.5 Draining and filling cooling system
  52
• 1.6 Removing and installing radiator and radiator fan
  54
• Fuel supply system
  55
• 1 Removing and installing parts of fuel supply system
  55
• 1.1 Exploded view of fuel tank and attachments
  55
• 1.2 Safety precautions when working on the fuel supply system
  57
• 1.3 Rules for cleanliness
  57
• 1.4 Removing and installing fuel tank
  57
• 1.5 Removing and installing fuel gauge sender
  58
• 1.6 Gravity valve
  59
• 1.7 Check valve
  59
• 1.8 Adjusting throttle cable
  59
• 1.9 Fuel pump and fuel filter
  59
• 1.10 Checking fuel pump non-return valve
  65
• Mixture preparation, Injection
  66
• 1 Motronic injection and ignition system
  66
• 1.1 Exploded view of component fitting locations
  66
• 1.2 Exploded view of injection system
  66
• 1.3 Exploded view of intake manifold
  69
• 1.4 Exploded view of air cleaner
  70
• 1.5 Safety precautions
  71
• 1.6 Rules for cleanliness
  71
• 1.7 Technical data
  72
• 1.8 Idling check
  72
• 1.9 Checking and adjusting CO content
  72
• 1.10 Performing basic setting
  72
• 1.11 Checking electrical components of injection system
  72
• 1.12 Matching engine electronic control unit to electronic immobilizer
  72
• Exhaust system
  73
• 1 Exploded view of exhaust system
  73
• Ignition system
  75
• 1 Motronic injection and ignition system
  75
• 1.1 Exploded view of ignition system
  75
• 1.2 Safety precautions
  76
• 1.3 Test data, spark plug
  76
• 1.4 Removing and installing distributor
  77
• 1.5 Checking ignition timing
  78
• 1.6 Checking Hall sender
  78
• 1.7 Checking knock sensor
  80
• 1.8 Checking ignition transformer
  82
• 1.9 Checking ignition transformer output stage
  82