5-cyl. injection engine (4-valve)

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
  4
• 1.2 Securing engine to assembly stand
  8
• 1.3 Notes on installing
  9
• 1.4 Aligning engine and gearbox mountings
  11
• 1.5 Torque settings
  12
• 1.6 Additional information and removal instructions for vehicles with air conditioner
  13
• Crankshaft group
  14
• 1 Dismantling and assembling engine
  14
• 1.1 Parts l and ll - Assembly overview
  14
• 1.2 Part I: Assembly overview - Chain drive
  16
• 1.3 Part II: Crankshaft drive
  18
• 1.4 Removing and installing poly V-belt
  20
• 2 Removing and installing sealing flange and dual mass flywheel/drive plate
  22
• 2.1 Assembly overview
  22
• 2.2 Renewing crankshaft oil seal, vibration damper end
  24
• 2.3 Removing and installing drive plate
  25
• 2.4 Removing and installing oil seal, flywheel end
  27
• 3 Removing and installing crankshaft
  29
• 3.1 Assembly overview
  29
• 4 Dismantling and assembling pistons and conrods
  32
• 4.1 Assembly overview
  32
• 4.2 Piston and cylinder dimensions
  35
• Cylinder head, valve gear
  36
• 1 Removing and installing cylinder head
  36
• 1.1 Assembly overview
  36
• 1.2 Assembly overview - Cover part
  39
• 1.3 Removing and installing cylinder head cover
  42
• 1.4 Removing and installing cylinder head
  46
• 1.5 Checking valve timing
  52
• 1.6 Adjusting valve timing
  53
• 1.7 Checking compression
  58
• 2 Repairing valve gear
  61
• 2.1 Assembly overview
  61
• 2.2 Reworking valve seats
  65
• 2.3 Removing and installing camshafts
  67
• 2.4 Checking valve guides
  73
• 2.5 Renewing valve stem seals
  74
• Lubrication
  77
• 1 Removing and installing parts of lubrication system
  77
• 1.1 Engine oil
  77
• 1.2 Assembly overview
  77
• 1.3 Assembly overview - Oil filter housing
  80
• 1.4 Assembly overview - Oil pump
  81
• 1.5 Removing and installing sump
  82
• 1.6 Checking oil pressure and oil pressure switch
  84
• Cooling
  87
• 1 Removing and installing parts of cooling system
  87
• 1.1 Assembly overview - Parts of cooling system, body side
  87
• 1.2 Assembly overview - Parts of cooling system, engine side
  89
• 1.3 Coolant hose schematic diagram
  91
• 1.4 Assembly overview - Thermostat housing
  91
• 1.5 Draining and filling coolant
  93
• 1.6 Removing and installing radiator and fan
  96
• 1.7 Removing and installing coolant pump
  98
• 1.8 Checking continued coolant circulation pump V51
  99
• 1.9 Checking radiator fan
  101
• Fuel supply system
  103
• 1 Removing and installing parts of fuel supply system
  103
• 1.1 Assembly overview - Fuel tank with attachments and fuel filter
  103
• 1.2 Safety precautions when working on fuel supply system
  109
• 1.3 Rules for cleanliness
  110
• 1.4 Removing, installing and checking suction jet pump: vehicles with four-wheel drive
  110
• 1.5 Crash fuel shut-off
  113
• 1.6 Removing and installing fuel delivery unit
  113
• 1.7 Removing and installing fuel gauge sender G
  116
• 1.8 Removing and installing fuel tank
  116
• 1.9 Checking fuel pump
  118
• 2 Checking electronic power control (EPC)
  125
• 2.1 Function of EPC system
  125
• 2.2 Assembly overview
  125
• 3 Activated charcoal filter system
  127
• 3.1 Function
  127
• 3.2 Assembly overview
  127
• 3.3 Checking fuel tank breather
  128
• Mixture preparation - injection
  131
• 1 Repairing injection system
  131
• 1.1 Fitting locations overview
  131
• 1.2 General notes on injection
  133
• 1.3 Assembly overview - Parts of injection system
  134
• 1.4 Assembly overview - Intake manifold
  137
• 1.5 Assembly overview - Fuel rail
  138
• 1.6 Assembly overview - Air cleaner
  139
• 1.7 Safety precautions
  140
• 1.8 Rules for cleanliness
  141
• 1.9 Technical data
  141
• 2 Checking components
  142
• 2.1 Checking injectors
  142
• 2.2 Checking fuel pressure regulator and holding pressure
  144
• 3 Engine control unit
  148
• 3.1 Removing and installing engine control unit
  148
• 3.2 Adapting components
  148
• 3.3 Reading and erasing engine control unit fault memory
  149
• Exhaust system
  151
• 1 Removing and installing parts of exhaust system
  151
• 1.3 Assembly overview - Silencer with mountings: vehicles with front-wheel drive
  155
• 1.4 Assembly overview - Silencer with mountings: vehicles with four-wheel drive
  157
• 2 Secondary air system
  158
• 2.1 Function
  158
• 2.2 Assembly overview - Parts of secondary air system
  158
• 2.3 Checking combination valve
  160
• Ignition system
  162
• 1 Repairing ignition system
  162
• 1.1 Assembly overview - Parts of ignition system
  162
• 1.2 Safety precautions
  163
• 1.3 Test data, spark plugs
  164