4-cyl. injection engine (toothed belt drive)

Kapitelübersicht

• Technical data
  1
• 1 Technical data
  1
• 1.1 Engine number
  1
• 1.2 Engine data
  1
• Removing and installing engine
  3
• 1 Removing and installing engine
  3
• 1.1 Removing engine
  5
• 1.2 Securing engine to assembly stand
  7
• 1.3 Installing engine
  7
• 1.4 Specified torques
  10
• 1.5 Assembly mountings
  10
• 1.6 Additional information and assembly work for vehicles with air conditioner
  11
• Crankshaft group
  12
• 1 Dismantling and assembling engine
  12
• 1.1 Assembly overview - parts l and ll
  12
• 1.2 Assembly overview - part I, belt drive
  14
• 1.3 Assembly overview - part II, cylinder block
  15
• 1.4 Removing and installing poly-V belt
  17
• 2 Cylinder block, sealing flange
  19
• 2.1 Assembly overview
  19
• 2.2 Pulling needle bearing out of and driving into crankshaft
  20
• 2.3 Renewing crankshaft oil seal - belt pulley end
  21
• 2.4 Poly V-belt pulley securing bolt tightening procedure
  23
• 2.5 Removing and installing drive plate
  24
• 2.7 Renewing crankshaft sealing flange - flywheel end ( assembly tool T10134 )
  26
• 2.8 Renewing crankshaft sealing flange - flywheel end ( assembly tool T10017 )
  34
• 2.9 Crankshaft dimensions
  41
• 3 Pistons and conrods
  43
• 3.1 Assembly overview
  43
• 3.2 Piston and cylinder dimensions
  46
• Cylinder head, valve gear
  47
• 1 Cylinder head
  47
• 1.1 Assembly overview
  47
• 1.2 Checking valve timing
  49
• 1.3 Removing, installing and tensioning toothed belt
  50
• 1.4 Checking semi-automatic toothed belt tensioner
  55
• 1.5 Removing and installing camshaft housing
  59
• 1.6 Removing and installing cylinder head
  61
• 1.7 Checking compression
  66
• 2 Valve gear
  68
• 2.1 Assembly overview
  68
• 2.2 Reworking valve seats
  71
• 2.3 Renewing camshaft oil seals
  72
• 2.4 Checking valve guides
  74
• 2.5 Renewing valve stem seals
  75
• Lubrication
  77
• 1 Parts of lubrication system
  77
• 1.1 Engine oil:
  77
• 1.2 Assembly overview
  77
• 1.3 Removing and installing oil sump
  80
• 1.4 Removing and installing oil pump
  81
• 1.5 Checking oil pressure and oil pressure switch
  84
• Cooling
  86
• 1 Parts of cooling system
  86
• 1.1 Assembly overview - parts of cooling system, body side
  86
• 1.2 Assembly overview - parts of cooling system, body side
  88
• 1.3 Assembly overview - parts of cooling system, engine side
  89
• 1.4 Connection diagram for coolant hoses
  91
• 1.5 Connection diagram for coolant hoses
  91
• 1.6 Draining and adding coolant
  93
• 1.7 Removing and installing radiator
  96
• 1.8 Removing and installing coolant pump
  98
• Fuel supply system
  100
• 1 Parts of fuel supply system
  100
• 1.1 Assembly overview - fuel tank with attachments
  100
• 1.2 Safety regulations for working on fuel supply
  103
• 1.3 Rules for cleanliness
  104
• 1.4 Removing and installing fuel delivery unit
  104
• 1.5 Removing and installing fuel gauge sender
  106
• 1.6 Removing and installing fuel tank
  106
• 1.7 Crash fuel shut-off
  108
• 1.8 Checking fuel pump (engine codes AUA, AUB, BBY, BBZ, BKY and BUD)
  108
• 1.9 Checking fuel pump (engine code CGGB)
  117
• 1.10 Bleeding fuel system
  124
• 2 Electronic power control (EPC)
  127
• 2.1 Assembly overview
  127
• 3 Activated charcoal filter system
  128
• 3.1 Assembly overview - parts of activated charcoal filter system
  128
• 3.2 Checking fuel tank breather
  129
• Mixture preparation - injection
  130
• 1 Injection system
  130
• 1.1 General notes on injection
  130
• 1.2 Assembly overview - parts of injection system
  130
• 1.3 Assembly overview - intake manifold
  132
• 1.4 Assembly overview - intake manifold
  133
• 1.5 Assembly overview - fuel rail with injectors
  135
• 1.6 Assembly overview - air filter
  135
• 1.7 Assembly overview - air filter
  137
• 1.8 Removing and installing air filter housing
  139
• 1.9 Cleaning throttle valve module J338
  140
• 1.10 Checking injectors
  141
• 1.11 Checking intake air preheating
  142
• 1.12 Safety precautions
  143
• 1.13 Rules for cleanliness
  144
• 1.14 Technical data
  145
• 2 Engine control unit J623
  146
• 2.1 Removing and installing engine (motor) control unit J623
  146
• 2.2 Removing and installing anti-theft engine control unit J623
  146
• Exhaust system
  150
• 1 Parts of the exhaust system
  150
• 1.1 Assembly overview - front exhaust system with attachments
  150
• 1.2 Assembly overview - front exhaust system with attachments
  152
• 1.3 Assembly overview - silencers with mountings
  154
• 2 Exhaust gas recirculation system
  155
• 2.1 Assembly overview
  155
• Ignition system
  157
• 1 Ignition system
  157
• 1.1 General notes on ignition system
  157
• 1.2 Assembly overview - parts of ignition system
  157
• 1.3 Safety precautions
  159
• 1.4 Test data, spark plugs
  160