4-Cyl. injection engine (cross-flow cylinder head), 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 Notes on installing
  6
• 1.4 Tightening torques
  7
• 1.5 Assembly mountings
  8
• 1.6 Replacing engine carrier rubber mounting
  10
• 1.7 Additional information and removal instructions for vehicles with air conditioner
  11
• Crankshaft group
  13
• 1 Dismantling and assembling engine
  13
• 1.1 Dismantling and assembling engine
  13
• 1.2 Removing and installing ribbed belt
  28
• 1.3 Removing and installing toothed belt
  31
• 2 Removing and installing sealing flange and pressure plate/drive plate
  35
• 2.1 Removing and installing sealing flange and pressure plate/drive plate
  35
• 2.2 Renewing crankshaft oil seal -pulley side-
  39
• 2.3 Removing and installing drive plate
  42
• 3 Removing and installing crankshaft
  45
• 3.1 Removing and installing crankshaft
  45
• 3.2 Crankshaft dimensions
  47
• 4 Dismantling and assembling pistons and conrods
  48
• 4.1 Dismantling and assembling pistons and conrods
  48
• 4.2 Piston and cylinder dimensions
  54
• Cylinder head, Valve gear
  55
• 1 Removing and installing cylinder head
  55
• 1.1 Removing and installing cylinder head
  55
• 1.2 Removing and installing cylinder head
  62
• 1.3 Checking compressions
  64
• 2 Servicing valve gear
  66
• 2.1 Servicing valve gear
  66
• 2.2 Reworking valve seats
  72
• 2.3 Removing and installing camshaft oil seal
  75
• 2.4 Removing and installing camshaft
  77
• 2.5 Checking hydraulic bucket tappets
  79
• 2.6 Checking valve guides
  80
• 2.7 Renewing valve guides
  81
• 2.8 Renewing valve stem seals
  83
• Lubrication
  86
• 1 Removing and installing parts of the lubrication system
  86
• 1.1 Removing and installing parts of the lubrication system
  86
• 1.2 Checking oil pressure and oil pressure switch
  93
• Cooling system
  95
• 1 Removing and installing parts of cooling system
  95
• 1.1 Removing and installing parts of cooling system
  95
• 1.2 Parts of cooling system body side
  96
• 1.3 Parts of cooling system - engine side
  102
• 1.4 Dismantling and assembling coolant pump
  109
• 1.5 Draining and filling cooling system
  111
• 1.6 Removing and installing radiator and radiator fan
  113
• Fuel supply system
  115
• 1 Removing and installing parts of fuel supply system
  115
• 1.1 Removing and installing parts of fuel supply system
  115
• 1.2 Removing and installing fuel tank with its attachments and fuel filter
  116
• 1.3 Safety precautions when working on the fuel supply system
  121
• 1.4 Rules for cleanliness
  122
• 1.5 Adjusting throttle cable
  122
• 1.6 Removing and installing fuel delivery unit
  125
• 1.7 Checking fuel pump
  127
• 1.8 Crash fuel shut-off
  128
• 2 Activated charcoal filter system
  132
• 2.1 Activated charcoal filter system
  132
• 2.2 Function
  132
• 2.3 Servicing parts of the activated charcoal filter system
  134
• 2.4 Checking activated charcoal filter solenoid valve 1
  139
• 2.5 Checking fuel tank breather
  141
• Exhaust system
  144
• 1 Removing and installing parts of exhaust system
  144
• 1.1 Removing and installing parts of exhaust system
  144
• 1.2 Exhaust manifold, front exhaust pipe and catalyst with attachments
  144
• 1.3 Silencer with mountings
  148
• 1.4 Checking catalyst
  150
• 2 Secondary air system
  152
• 2.1 Secondary air system
  152
• 2.2 Function
  152
• 2.3 Removing and installing parts of the secondary air system
  153
• 2.4 Checking combi-valve
  156
• 2.5 Checking secondary air pump motor
  158
• 2.6 Checking secondary air inlet valve
  159