4-cylinder injection engine (crossflow cylinder head), mechanics

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 Notes on removing
  3
• 1.2 Notes on installing
  5
• 1.3 Specified torques
  6
• 1.4 Assembly mountings
  7
• 1.5 Renewing engine carrier rubber mounting
  8
• Crankshaft group
  11
• 1 Dismantling and assembling engine
  11
• 1.1 Assembly overview
  11
• 1.2 Removing and installing poly V-belt
  18
• 1.3 Removing, installing and tensioning toothed belt
  20
• 2 Removing and installing sealing flange and pressure plate/drive plate
  24
• 2.1 Assembly overview – sealing flanges
  24
• 2.2 Renewing crankshaft oil seal - pulley end
  26
• 2.3 Removing and installing drive plate
  28
• 3 Crankshaft
  30
• 3.1 Assembly overview - crankshaft
  30
• 3.2 Crankshaft dimensions
  31
• 4 Dismantling and assembling pistons and conrods
  32
• 4.1 Assembly overview - pistons and conrods
  32
• 4.2 Checking pistons, piston rings and cylinder bores
  33
• 4.3 Piston and cylinder dimensions
  35
• Cylinder head, valve gear
  36
• 1 Cylinder head
  36
• 1.1 Assembly overview - cylinder head
  36
• 1.2 Removing and installing cylinder head
  40
• 1.3 Checking compression
  42
• 2 Valve gear
  44
• 2.1 Assembly overview - valve gear
  44
• 2.2 Reworking valve seats
  48
• 2.3 Removing and installing camshaft oil seal
  49
• 2.4 Removing and installing camshaft
  51
• 2.5 Checking hydraulic bucket tappets
  53
• 2.6 Checking valve guides
  54
• 2.7 Renewing valve guides
  54
• 2.8 Renewing valve stem seals
  56
• Lubrication
  59
• 1 Parts of lubrication system
  59
• 1.1 Engine oil
  59
• 1.2 Assembly overview - parts of lubrication system
  59
• 1.3 Checking oil pressure and oil pressure switch
  62
• Cooling
  64
• 1 Removing and installing parts of cooling system
  64
• 1.1 Parts of cooling system, body side
  64
• 1.2 Parts of cooling system - engine side
  67
• 1.3 Dismantling and assembling coolant pump
  71
• 1.4 Draining and filling coolant
  71
• 1.5 Removing and installing radiator and fan
  74
• Fuel supply system
  76
• 1 Removing and installing parts of fuel supply system
  76
• 1.1 Safety precautions when working on fuel supply system
  76
• 1.2 Rules for cleanliness
  77
• 1.3 Assembly overview – fuel tank with attachments and fuel filter
  77
• 1.4 Adjusting accelerator cable
  80
• 1.5 Removing and installing fuel delivery unit
  82
• 1.6 Checking fuel pump
  84
• 1.7 Crash fuel shut-off
  88
• 2 Activated charcoal filter system
  89
• 2.1 Function
  89
• 2.2 Assembly overview - activated charcoal filter system
  90
• 2.3 Test solenoid valve 1 for activated charcoal filter
  92
• 2.4 Checking fuel tank breather
  94
• Exhaust system
  96
• 1 Removing and installing parts of exhaust system
  96
• 1.2 Silencer with mountings
  99
• 1.3 Checking catalytic converter
  100
• 2 Secondary air system
  103
• 2.1 Function
  103
• 2.2 Removing and installing components of secondary air system
  103
• 2.3 Checking combination valve
  105
• 2.4 Checking secondary air pump motor
  106
• 2.5 Checking secondary air inlet valve
  107