4-Cyl. injection engine (G charger), 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
  3
• 1.3 Notes on installing
  4
• 1.4 Tightening torques
  5
• 1.5 Assembly mountings
  5
• 1.6 Aligning engine and gearbox
  6
• 1.7 Renewing engine carrier rubber mounting
  7
• 1.8 Additional information and removal instructions for vehicles with air conditioner
  7
• Crankshaft group
  9
• 1 Dismantling and assembling engine
  9
• 1.1 Dismantling and assembling engine
  9
• 1.2 Removing and installing ribbed belt
  24
• 1.3 Removing and installing toothed belt
  25
• 2 Removing and installing sealing flange and flywheel/drive plate
  29
• 2.1 Removing and installing sealing flange and flywheel/drive plate
  29
• 2.2 Renewing crankshaft oil seal - pulley end -
  32
• 2.3 Removing and installing drive plate
  33
• 2.4 Subsequent marking of ignition timing notch
  35
• 3 Removing and installing crankshaft
  36
• 3.1 Removing and installing crankshaft
  36
• 3.2 Crankshaft dimensions
  38
• 4 Dismantling and assembling pistons and conrods
  39
• 4.1 Dismantling and assembling pistons and conrods
  39
• 4.2 Piston and cylinder dimensions
  45
• Cylinder head, Valve gear
  46
• 1 Removing and installing cylinder head
  46
• 1.1 Removing and installing cylinder head
  46
• 1.2 Removing and installing cylinder head
  50
• 1.3 Checking compressions
  51
• 2 Servicing valve gear
  52
• 2.1 Servicing valve gear
  52
• 2.2 Reworking valve seats
  58
• 2.3 Removing and installing camshaft oil seal
  60
• 2.4 Removing and installing camshaft
  61
• 2.5 Checking hydraulic bucket tappets
  63
• 2.6 Checking valve guides
  63
• 2.7 Renewing valve guides
  64
• 2.8 Renewing valve stem seals
  64
• Lubrication
  66
• 1 Removing and installing parts of the lubrication system
  66
• 1.1 Removing and installing parts of the lubrication system
  66
• 1.2 Checking oil pressure and oil pressure switch
  73
• Cooling system
  75
• 1 Removing and installing parts of cooling system
  75
• 1.1 Removing and installing parts of cooling system
  75
• 1.2 Parts of cooling system body side
  76
• 1.3 Parts of cooling system - engine side
  79
• 1.4 Dismantling and assembling coolant pump
  83
• 1.5 Draining and filling cooling system
  85
• 1.6 Checking radiator fan run-on
  86
• Fuel supply system
  88
• 1 Removing and installing parts of fuel supply system
  88
• 1.1 Removing and installing parts of fuel supply system
  88
• 1.2 Removing and installing fuel tank with attachments >09.89
  89
• 1.3 Removing and installing, dismantling and assembling pump reservoir >09.89
  93
• 1.4 Removing and installing fuel tank with attachments and fuel filter 10.89 >
  96
• 1.5 Servicing fuel delivery unit 10.89...07.91
  101
• 1.6 Safety precautions when working on the fuel supply system
  105
• 1.7 Rules for cleanliness
  105
• 2 Servicing fuel supply system
  106
• 2.1 Servicing fuel supply system
  106
• 2.2 Adjusting throttle cable
  106
• 2.3 Removing and installing fuel delivery unit 10.89 >
  107
• 2.4 Dismantling and assembling fuel delivery unit 10.89...07.91
  108
• 2.5 Checking fuel pump(s)
  109
• 2.6 Checking fuel pump run-on
  113
• 2.7 Removing and installing parts of the activated charcoal filter system
  115
• 2.8 Checking activated charcoal filter shut-off valve
  116
• Charging
  117
• 1 Charge air system with G-charger
  117
• 1.1 Charge air system with G-charger
  117
• 1.2 Removing and installing parts of the charge air system
  117
• 1.3 Checking charge air system for leaks
  124
• 1.4 Checking boost pressure
  128
• Exhaust system
  130
• 1 Removing and installing parts of exhaust system
  130
• 1.1 Removing and installing parts of exhaust system
  130