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 Securing engine to assembly stand
  8
• 1.4 Notes on installing
  8
• 1.5 Tightening torques
  10
• 1.6 Assembly mounting
  10
• 1.7 Additional information and removal instructions for vehicles with air conditioner
  12
• Crankshaft group
  13
• 1 Dismantling and assembling engine
  13
• 1.1 Dismantling and assembling engine
  13
• 1.2 Removing and installing ribbed belt
  20
• 1.3 Checking semi-automatic toothed belt tensioning roller
  23
• 2 Removing and installing cylinder block, sealing flange and flywheel/drive plate
  25
• 2.1 Removing and installing cylinder block, sealing flange and flywheel/drive plate
  25
• 2.2 Aluminium cylinder block
  26
• 2.3 Renewing crankshaft oil seal -belt pulley end
  29
• 2.4 Removing and installing drive plate
  31
• 2.5 Renewing crankshaft sealing flange -flywheel end-
  34
• 2.6 Crankshaft dimensions
  43
• 3 Dismantling and assembling pistons and conrods
  44
• 3.1 Dismantling and assembling pistons and conrods
  44
• 3.2 Piston and cylinder dimensions
  49
• Cylinder head, Valve gear
  51
• 1 Removing and installing cylinder head
  51
• 1.1 Removing and installing cylinder head
  51
• 1.2 Removing, installing and tensioning toothed belts
  56
• 1.3 Removing and installing cylinder head
  59
• 1.4 Checking compression pressures
  63
• 2 Servicing valve gear
  65
• 2.1 Servicing valve gear
  65
• 2.2 Reworking valve seats
  71
• 2.3 Replacing camshaft oil seal
  73
• 2.4 Removing and installing cylinder head cover and camshaft
  75
• 2.5 Checking valve guides
  78
• 2.6 Renewing valve stem seals
  80
• Lubrication
  83
• 1 Removing and installing parts of the lubrication system
  83
• 1.1 Removing and installing parts of the lubrication system
  83
• 1.2 Removing and installing oil sump
  88
• 1.3 Removing and installing oil pump
  90
• 1.4 Checking oil pressure and oil pressure switch
  93
• Cooling system
  96
• 1 Removing and installing parts of cooling system
  96
• 1.1 Removing and installing parts of cooling system
  96
• 1.2 Parts of cooling system body side
  97
• 1.3 Parts of cooling system engine side
  100
• 1.4 Coolant hose connection diagram
  104
• 1.5 Draining and filling cooling system
  105
• 1.6 Removing and installing radiator
  107
• Fuel supply system
  109
• 1 Removing and installing parts of fuel supply system
  109
• 1.1 Removing and installing parts of fuel supply system
  109
• 1.2 Removing and installing fuel tank with its attachments and fuel filter
  110
• 1.3 Safety precautions when working on the fuel supply system
  115
• 1.4 Rules for cleanliness
  116
• 1.5 Crash fuel shut-off
  116
• 1.6 Removing and installing fuel delivery unit
  116
• 1.7 Removing and installing fuel gauge sender
  117
• 1.8 Removing and installing fuel tank
  118
• 1.9 Checking fuel pump
  119
• 2 Electronic power control (EPC)
  125
• 2.1 Electronic power control (EPC)
  125
• 2.2 Function of EPC system
  125
• 2.3 Servicing parts of electronic power control (EPC)
  127
• 2.4 Checking electronic accelerator warning lamp
  128
• 2.5 Checking accelerator pedal position sender
  130
• 3 Activated charcoal filter system
  133
• 3.1 Activated charcoal filter system
  133
• 3.2 Function
  133
• 3.3 Servicing parts of the activated charcoal filter system
  134
• 3.4 Checking tank venting valve
  135
• 3.5 Checking fuel tank breather
  137
• Exhaust system
  140
• 1 Removing and installing parts of exhaust system
  140
• 1.1 Removing and installing parts of exhaust system
  140
• 1.2 Exhaust manifold, front exhaust pipe and catalyst with attachments
  141
• 1.3 Silencer with mountings
  145
• 1.4 Checking catalyst
  147
• 2 Exhaust gas recirculation system
  150
• 2.1 Exhaust gas recirculation system
  150
• 2.2 Servicing parts of exhaust gas recirculation system
  151
• 2.3 Checking potentiometer for exhaust gas recirculation (G212)
  153