3 - Cyl. injection engine

Chapter overview

• Technical data
  1
• 1 \--- Change history ---
  1
• 2 Safety instructions
  2
• 2.1 Safety measures regarding work on the fuel supply
  2
• 2.2 Safety measures in test drives using testing and measurement devices
  3
• 2.3 Safety measures when working on the cooling system
  4
• 2.4 Safety measures when working on the ignition system
  5
• 3 Identification
  6
• 3.1 Engine number/engine characteristics
  6
• 4 Repair instructions
  8
• 4.1 Cleaning rules
  8
• 4.2 General instructions
  8
• 4.3 General repair instructions
  8
• 4.4 Foreign bodies on the engine
  9
• 4.5 Contact corrosion
  9
• 4.6 Connection installation and fastening
  9
• 4.7 Radiator and capacitor installation
  9
• Removing and installing engine
  10
• 1 Engine - remove and install
  10
• 1.1 Engine - removal
  10
• 1.2 Engine - separate gearbox
  18
• 1.3 Secure the engine to the engine and gearbox swivelling stand
  20
• 1.4 Engine - installation
  22
• 2 Power-drive unit supports
  24
• 2.1 Power unit brackets - assembly overview
  24
• 2.2 Power unit bracket (engine side) - remove and install
  26
• 2.3 Power-drive unit supports (gearbox side) - remove and install
  27
• 2.4 Pendulum support (torque limiter) - remove and install
  30
• 2.5 Support the engine in assembly position
  30
• 2.6 Power-drive group support (engine side) - adjust
  33
• 2.7 Additional notes and installation works in vehicles with air conditioning
  33
• Crankshaft group
  35
• 1 Cylinder block (pulley side)
  35
• 1.1 Poly-V belt mechanism - assembly overview
  35
• 1.2 Poly-V belt mechanism - assembly overview
  36
• 1.3 Cylinder block (pulley side) - assembly overview
  37
• 1.4 Poly-V belt - remove and install
  39
• 1.5 Poly-V belt - remove and install
  41
• 1.6 Poly-V belt tensioner - remove and install
  43
• 1.7 Engine console - remove and install
  44
• 1.8 Crankshaft pulley (vibration damper) - remove and install
  45
• 1.9 Crankshaft seal (pulley side) - replace
  46
• 2 Cylinder block (gearbox side)
  50
• 2.1 Cylinder block (gearbox side) - assembly overview
  50
• 2.2 Flywheel - remove and install
  51
• 2.3 Crankshaft flange (flywheel side) - replace
  52
• 3 Crankshaft
  61
• 3.1 Crankshaft - dimensions
  61
• 4 Pistons and conrods
  62
• 4.1 Pistons and conrods - assembly overview
  62
• 4.2 Pistons - remove and install
  64
• 4.3 Pistons, rings, and cylinders - check
  65
• 4.4 Conrod and cap (new part) - separate
  67
• 4.5 Conrod radial clearance - check
  68
• 4.6 Oil spray jet and valve - remove and install
  68
• Cylinder head, valve gear
  70
• 1 Cylinder head - assembly and disassembly
  70
• 1.1 Cylinder head - assembly overview
  70
• 1.2 Engine cylinder head - remove and install
  72
• 1.3 Cylinder head cover with exhaust and inlet camshafts - remove and install
  78
• 1.4 Compression - check
  87
• 2 Toothed belt drive
  91
• 2.1 Toothed belt - remove and install
  91
• 2.2 Valve timing - check
  102
• 2.3 Valve timing - adjust
  106
• 3 Camshaft mechanism
  119
• 3.1 Camshaft mechanism - assembly overview
  119
• 3.2 Crankshaft - check axial clearance
  121
• 3.3 Crankshaft seal - replace
  122
• 3.4 Inlet camshaft regulator - remove and install
  138
• 3.5 Exhaust camshaft sprocket - remove and install
  144
• 3.6 Camshaft adjustment valve 1 N205 - remove and install
  149
• 3.7 Valve stem sealant - replace
  149
• 4 Inlet and exhaust valves
  156
• 4.1 Valve guides - check
  156
• 4.2 Valves - check
  156
• 4.3 Valve dimensions
  157
• Lubrication
  158
• 1 Crankcase/oil pump
  158
• 1.1 Crankcase/oil pump - assembly overview
  158
• 1.2 Engine oil
  161
• 1.3 Lower sump - remove and install
  162
• 1.4 Upper crankcase - remove and install
  163
• 1.5 Oil pump - remove and install
  167
• 2 Engine crankcase ventilation
  170
• 2.1 Engine crankcase ventilation - assembly overview
  170
• 2.2 Crankcase ventilation device - remove and install
  171
• 3 Oil filter/ Oil pressure switch F1
  173
• 3.1 Oil pressure switch F1 - remove and install
  173
• 3.2 Oil pressure and Oil pressure switch F1 - check
  174
• 3.3 Oil filter - remove and install
  176
• Cooling
  178
• 1 Cooling system/coolant
  178
• 1.1 Hose connection diagram for cooling system
  178
• 1.2 Cooling system - check air-tightness
  178
• 1.3 Coolant tank flap - check safety valve
  180
• 1.4 Cooling system - drainage and replenishment
  181
• 2 Water pump/coolant adjustment
  190
• 2.1 Water pump - assembly overview
  190
• 2.2 Water pump - remove and install
  192
• 2.3 Thermostat valve - assembly overview
  196
• 2.4 Thermostat valve - removal and installation
  198
• 2.5 Water pump toothed belt - remove and install
  203
• 2.6 Water pump sprocket - remove and install
  206
• 2.7 Coolant temperature sensor G62 - remove and install
  207
• 3 Radiator/ Radiator fan V7
  210
• 3.1 Radiator/ Radiator fan V7 - assembly overview
  210
• 3.2 Radiator - remove and install
  212
• 3.3 Radiator fan V7 air deflector - remove and install
  215
• 3.4 Radiator fan V7 - remove and install
  218
• Fuel supply system
  221
• 1 Fuel reservoir
  221
• 1.1 Fuel tank - assembly overview
  221
• 1.2 Cold start system components - remove and install
  225
• 1.3 Fuel reservoir - remove and install
  226
• 1.4 Fuel tank - drain
  230
• 2 Fuel pump (pre-supply pump) G6 / Fuel gauge sensor G
  237
• 2.2 Fuel pump (pre-supply pump) G6 / Fuel gauge sensor G - remove and install
  239
• 2.3 Fuel gauge sensor G - remove and install
  243
• 3 Quick-release fastener with button
  245
• 3.1 Quick-release fastener with button - disconnect
  245
• 4 Fuel filter
  249
• 4.1 Fuel filter - remove and install
  249
• 5 Activated charcoal filter system
  250
• 5.1 Activated charcoal filter system - operation
  250
• 5.2 Activated charcoal filter system - assembly overview
  251
• 5.3 Fuel tank ventilation system - check
  252
• 5.4 Activated charcoal filter - remove and install
  258
• 6 Engine power electronic adjustment (electronic accelerator)
  263
• 6.1 Accelerator pedal module (electric throttle) - assembly overview
  263
• 6.2 Accelerator pedal module (electric throttle) - remove and install
  264
• 7 Fuel pump (pre-supply pump) G6
  266
• 7.1 Fuel pump (pre-supply pump) G6 - check
  266
• Mixture preparation - injection
  287
• 1 Injection system
  287
• 1.1 Injection system - assembly overview
  287
• 1.2 Combustion system - assembly overview
  290
• 2 Injection valves
  292
• 2.1 Fuel rail with injection valves - assembly overview
  292
• 2.2 Injection valves - remove and install
  295
• 2.3 Injection valves - check
  299
• 3 Air cleaner
  305
• 3.1 Air filter - assembly overview
  305
• 3.2 Air filter - remove and install
  306
• 4 Intake manifold
  307
• 4.1 Intake manifold - assembly overview
  307
• 4.2 Intake manifold - remove and install
  308
• 4.3 Throttle butterfly valve control unit J338 - remove and install
  310
• 4.4 Throttle valve control unit J338 - clean
  312
• 5 Transmitters and sensors
  313
• 6 Engine control unit J623
  315
• 6.1 Engine control unit J623 - assembly overview
  315
• 6.2 Engine control unit J623 - remove and install
  316
• 6.3 Engine control unit J623 support - remove and install
  319
• 7 Lambda probe
  320
• 7.1 Lambda probe - remove and install
  320
• Exhaust system
  324
• 1 Silencer/exhaust pipes
  324
• 1.1 Silencer - assembly overview
  324
• 1.2 Silencer/exhaust pipes - separation
  325
• 1.3 Silencer - remove and install
  326
• 1.4 Exhaust system - check air-tightness
  328
• 1.5 Double clamp - installation position
  329
• 2 Exhaust system
  330
• 2.1 Front exhaust pipe - assembly overview
  330
• 2.2 Catalytic converter - remove and install
  331
• Ignition system
  334
• 1 Ignition system
  334
• 1.1 Ignition system - assembly overview
  334
• 1.2 Ignition coils with final power stage - assembly overview
  335
• 1.3 Spark plugs Q - technical data
  336
• 1.4 Ignition coil with final power stage - remove and install
  336
• 1.5 Knock sensor 1 G61 - remove and install
  339
• 1.6 Hall Sensor G40 - remove and install
  340
• 1.7 Engine speed sensor G28 - remove and install
  341