4-Cyl. injection engine (4-valve, roller rocker arm), Mechanics

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Technical data
  1
• 1.2 Engine number
  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 mountings
  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
  22
• 1.3 Checking valve timing
  23
• 1.4 Removing, installing and tensioning toothed belts
  25
• 1.5 Checking semi-automatic toothed belt tensioning roller
  33
• 2 Removing and installing cylinder block, sealing flange and flywheel/drive plate
  37
• 2.1 Removing and installing cylinder block, sealing flange and flywheel/drive plate
  37
• 2.2 Aluminium cylinder block
  38
• 2.3 Renewing crankshaft oil seal -belt pulley end-
  41
• 2.4 Removing and installing drive plate
  43
• 2.5 Renewing crankshaft sealing flange -flywheel end-
  46
• 2.6 Crankshaft dimensions
  55
• 3 Dismantling and assembling pistons and conrods
  56
• 3.1 Dismantling and assembling pistons and conrods
  56
• 3.2 Piston and cylinder dimensions
  62
• Cylinder head, Valve gear
  63
• 1 Removing and installing cylinder head
  63
• 1.1 Removing and installing cylinder head
  63
• 1.2 Removing and installing camshaft housing
  67
• 1.3 Removing and installing cylinder head
  70
• 1.4 Checking compression pressures
  74
• 2 Servicing valve gear
  76
• 2.1 Servicing valve gear
  76
• 2.2 Reworking valve seats
  84
• 2.3 Replacing camshaft oil seals
  86
• 2.4 Checking valve guides
  88
• 2.5 Renewing valve guides
  88
• 2.6 Renewing valve stem seals
  89
• Lubrication
  92
• 1 Removing and installing parts of the lubrication system
  92
• 1.1 Removing and installing parts of the lubrication system
  92
• 1.2 Removing and installing oil sump
  97
• 1.3 Removing and installing oil pump
  99
• 1.4 Checking oil pressure and oil pressure switch
  102
• Cooling system
  104
• 1 Removing and installing parts of cooling system
  104
• 1.1 Removing and installing parts of cooling system
  104
• 1.2 Parts of cooling system body side
  105
• 1.3 Parts of cooling system engine side
  108
• 1.4 Coolant hose connection diagram
  113
• 1.5 Draining and filling cooling system
  114
• 1.6 Removing and installing radiator
  116
• 1.7 Removing and installing coolant pump
  118
• Fuel supply system
  120
• 1 Removing and installing parts of fuel supply system
  120
• 1.1 Removing and installing parts of fuel supply system
  120
• 1.2 Removing and installing fuel tank with its attachments and fuel filter
  121
• 1.3 Safety precautions when working on the fuel supply system
  126
• 1.4 Rules for cleanliness
  126
• 1.5 Removing and installing fuel delivery unit
  127
• 1.6 Removing and installing fuel gauge sender
  128
• 1.7 Removing and installing fuel tank
  128
• 1.8 Crash fuel shut-off
  129
• 1.9 Checking fuel pump
  130
• 2 Accelerator mechanism
  136
• 2.1 Accelerator mechanism
  136
• 2.2 Servicing accelerator mechanism
  137
• 2.3 Adjusting accelerator cable
  137
• 3 Checking electronic power control (EPC)
  140
• 3.1 Checking electronic power control (EPC)
  140
• 3.2 Function of EPC system
  141
• 3.3 Checking accelerator pedal position sender
  142
• 4 Activated charcoal filter system
  146
• 4.1 Activated charcoal filter system
  146
• 4.2 Function
  146
• 4.3 Servicing parts of the activated charcoal filter system
  147
• 4.4 Checking activated charcoal filter solenoid valve 1
  151
• 4.5 Checking fuel tank breather
  153
• Exhaust system
  155
• 1 Removing and installing parts of exhaust system
  155
• 1.1 Removing and installing parts of exhaust system
  155
• 1.2 Exhaust manifold, front exhaust pipe and catalyst with attachments
  156
• 1.3 Exhaust manifold, front exhaust pipe and catalyst with attachments
  158
• 1.4 Silencer with mountings
  161
• 1.5 Checking catalyst
  164
• 2 Exhaust gas recirculation system
  166
• 2.1 Exhaust gas recirculation system
  166
• 2.2 Servicing parts of exhaust gas recirculation system
  167
• 2.3 Checking exhaust gas recirculation valve (mechanical)
  169
• 2.4 Servicing parts of exhaust gas recirculation system
  171
• 2.5 Checking potentiometer for exhaust gas recirculation (G212)
  173