4-Cyl. Injection Engine (2 Valve, Roller Rocker Finger), Mechanics

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Technical data
  1
• 1.2 Engine number
  1
• 1.3 Engine data
  1
• Removing and installing engine
  3
• 1 Removing and installing engine
  3
• 1.1 Removing and installing engine
  3
• 1.2 Notes on removing
  4
• 1.3 Fastening the engine to the assembly stand
  8
• 1.4 Notes on installation
  9
• 1.5 Prescribed torque's
  10
• 1.6 Aligning engine and gearbox mountings
  11
• 1.7 Assembly mounting
  12
• Crankshaft group
  14
• 1 Dismantling and assembling the engine
  14
• 1.1 Dismantling and assembling the engine
  14
• 1.2 Removing and installing poly V-belt
  23
• 1.3 Checking semi-automatic toothed belt tensioning roller
  25
• 2 Removing and installing sealing flange and pressure plate/drive plate
  26
• 2.1 Removing and installing sealing flange and pressure plate/drive plate
  26
• 2.2 Renewing crankshaft oil seal, belt pulley end
  29
• 2.3 Removing and installing front sealing flange
  33
• 2.4 Removing and installing drive plate
  35
• 3 Removing and installing crankshaft
  38
• 3.1 Removing and installing crankshaft
  38
• 3.2 Colour markings
  42
• 3.3 Crankshaft dimensions
  42
• 4 Dismantling and assembling piston and conrod
  43
• 4.1 Dismantling and assembling piston and conrod
  43
• 4.2 Piston and cylinder dimensions
  48
• Cylinder head, Valve gear
  49
• 1 Removing and installing cylinder head
  49
• 1.1 Removing and installing cylinder head
  49
• 1.2 Removing, installing and tensioning toothed belts
  53
• 1.3 Removing and installing cylinder head
  60
• 1.4 Check compression pressures
  64
• 2 Servicing valve gear
  66
• 2.1 Servicing valve gear
  66
• 2.2 Reworking valve seats
  71
• 2.3 Renewing camshaft oil seal
  73
• 2.4 Removing and installing camshaft
  76
• 2.5 Checking valve guides
  81
• 2.6 Renewing valve stem seals
  82
• Lubrication
  85
• 1 Removing and installing parts of the lubrication system
  85
• 1.1 Removing and installing parts of the lubrication system
  85
• 1.2 Removing and installing oil sump
  93
• 1.3 Checking oil pressure and oil pressure switch
  96
• Cooling system
  98
• 1 Removing and installing parts of cooling system
  98
• 1.1 Removing and installing parts of cooling system
  98
• 1.2 Parts of cooling system body side
  99
• 1.3 Parts of cooling system engine side
  103
• 1.4 Coolant hose connection diagram
  107
• 1.5 Draining and filling coolant system
  108
• 1.6 Removing and installing the radiator
  111
• 1.7 Removing and installing coolant pump
  113
• 1.8 Removing and installing thermostat
  115
• Fuel supply system
  117
• 1 Removing and installing parts of fuel supply system
  117
• 1.1 Removing and installing parts of fuel supply system
  117
• 1.2 Removing and installing fuel tank with its attachments and fuel filter
  118
• 1.3 Safety precautions when working on the fuel supply system
  124
• 1.4 Rules for cleanliness
  124
• 1.5 Removing and installing fuel delivery unit
  125
• 1.6 Removing and installing fuel gauge sender
  126
• 1.7 Removing and installing fuel tank
  127
• 1.8 Checking fuel pump
  129
• 1.9 Crash fuel shut-off
  131
• 2 Checking electronic power control (EPC)
  137
• 2.1 Checking electronic power control (EPC)
  137
• 2.2 Function of EPC system
  138
• 2.3 Checking accelerator pedal position sender
  139
• 3 Activated charcoal canister system
  142
• 3.1 Activated charcoal canister system
  142
• 3.2 Function
  142
• 3.3 Servicing parts of the activated charcoal canister system
  143
• 3.4 Checking activated charcoal canister solenoid valve 1
  145
• 3.5 Checking fuel tank breather
  146
• Exhaust system
  149
• 1 Removing and installing parts of exhaust system
  149
• 1.1 Removing and installing parts of exhaust system
  149
• 1.2 Exhaust manifold, front exhaust pipe and catalytic converter with attachments
  150
• 1.3 Silencer with mountings
  154
• 1.4 Checking catalytic converter
  157
• 2 Secondary air system
  159
• 2.1 Secondary air system
  159
• 2.2 Function
  159
• 2.3 Removing and installing parts of the secondary air system
  160
• 2.4 Checking secondary air system
  164
• 2.5 Checking secondary air pump motor
  166
• 2.6 Checking combination valve
  172
• 3 Exhaust gas recirculation system
  172
• 3.1 Exhaust gas recirculation system
  172
• 3.2 Servicing parts of exhaust gas recirculation system
  173
• 3.3 Checking exhaust gas recirculation potentiometer (G212)
  176