4-Cyl. injection engine 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 Securing engine to repair stand
  5
• 1.4 Notes on installing
  6
• 1.5 Tightening torques
  6
• 1.6 Additional information and removal instructions for vehicles with air conditioner
  7
• Crankshaft group
  8
• 1 Dismantling and assembling engine
  8
• 1.1 Dismantling and assembling engine
  8
• 1.2 Installing toothed belt
  23
• 1.3 Adjusting alternator V-belt tension
  25
• 1.4 Removing and installing ribbed belt
  25
• 2 Dismantling and assembling cylinder block, crankshaft and flywheel
  27
• 2.1 Dismantling and assembling cylinder block, crankshaft and flywheel
  27
• 2.2 Renewing crankshaft oil seal - pulley end -
  33
• 2.3 Crankshaft dimensions
  34
• 2.4 Removing and installing drive plate
  35
• 3 Dismantling and assembling pistons and conrods
  37
• 3.1 Dismantling and assembling pistons and conrods
  37
• 3.2 Piston and cylinder dimensions
  41
• Cylinder head, Valve gear
  43
• 1 Removing and installing cylinder head
  43
• 1.1 Removing and installing cylinder head
  43
• 1.2 Removing and installing cylinder head
  48
• 1.3 Checking compressions
  49
• 2 Servicing valve gear
  50
• 2.1 Servicing valve gear
  50
• 2.2 Reworking valve seats
  56
• 2.3 Checking hydraulic bucket tappets
  58
• 2.4 Removing and installing camshaft oil seal
  59
• 2.5 Removing and installing camshaft
  60
• 2.6 Checking valve guides
  60
• 2.7 Renewing valve guides
  61
• 2.8 Renewing valve stem seals
  61
• Lubrication
  63
• 1 Removing and installing parts of the lubrication system
  63
• 1.1 Removing and installing parts of the lubrication system
  63
• 1.2 Checking oil pressure and oil pressure switch
  69
• Cooling system
  70
• 1 Removing and installing parts of cooling system
  70
• 1.1 Removing and installing parts of cooling system
  70
• 1.2 Parts of cooling system body side
  71
• 1.3 Parts of cooling system - engine side
  75
• 1.4 Draining and filling cooling system
  78
• 1.5 Removing radiator
  80
• 1.6 Checking radiator fan run-on thermo-switch
  81
• 1.7 Checking coolant circulation thermo-switch
  81
• Fuel supply system
  83
• 1 Removing and installing parts of fuel supply system
  83
• 1.1 Removing and installing parts of fuel supply system
  83
• 1.2 Removing and installing fuel tank with its attachments
  84
• 1.3 Servicing fuel delivery unit
  88
• 1.4 Safety precautions when working on the fuel supply system
  92
• 1.5 Rules for cleanliness
  92
• 1.6 Removing and installing fuel delivery unit
  92
• 1.7 Dismantling and assembling fuel delivery unit
  93
• 1.8 Checking fuel pump
  95
• 1.9 Checking fuel pumps relay
  98
• 1.10 Servicing accelerator mechanism
  99
• 1.11 Servicing the activated charcoal filter system
  101
• 1.12 Checking regulation of the activated charcoal filter system
  102
• Exhaust system
  104
• 1 Removing and installing parts of exhaust system
  104
• 1.1 Removing and installing parts of exhaust system
  104
• 1.2 Removing and installing clamping springs
  110
• 1.3 Tensioning or releasing spring clamps
  111
• 1.4 Retrofitting front exhaust pipe stop plate
  112